Are you in the market for high-density polyethylene (HDPE) pipes? Understanding their PSI (pounds per square inch) rating is crucial to ensure you choose the right pipe for your specific application. In this comprehensive guide, we will delve into the world of HDPE pipe PSI ratings, exploring what they mean, how they are determined, and why they are vital for a successful installation. Whether you&#;re a contractor, engineer, or DIY enthusiast, this article will provide you with the knowledge to make informed decisions and achieve optimal results.
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When it comes to selecting the right HDPE pipe for your project, understanding the PSI rating is of utmost importance. The PSI rating measures the strength and pressure capacity of the pipe, indicating how much pressure it can withstand without failure. It is crucial to choose a pipe with an appropriate PSI rating to ensure it can handle the demands of your specific application.
The Importance of PSI Ratings
The PSI rating of an HDPE pipe determines its ability to handle different pressure levels. Pipes with higher PSI ratings can withstand greater pressure, making them suitable for applications that involve higher fluid or gas pressures. On the other hand, pipes with lower PSI ratings are ideal for low-pressure applications. Understanding the significance of PSI ratings allows you to select the right pipe that can safely and efficiently handle the desired pressure.
PSI Rating and Pipe Material
The material composition of an HDPE pipe significantly affects its PSI rating. HDPE pipes are known for their excellent strength and durability, making them suitable for a wide range of applications. The material&#;s molecular structure and the manufacturing process contribute to its ability to withstand pressure. Understanding the relationship between material composition and PSI rating will help you choose a pipe that meets your requirements.
Several factors influence the PSI rating of HDPE pipes. Understanding these factors will allow you to make informed decisions when selecting the most suitable pipe for your project.
Material Composition
The material composition of the HDPE pipe plays a critical role in determining its PSI rating. HDPE pipes are made from high-density polyethylene, a thermoplastic known for its strength and durability. The molecular structure of the material ensures it can handle high pressure without deformation or failure. Different grades of HDPE may have varying PSI ratings, so it is essential to consider the material composition when selecting a pipe for your specific requirements.
Pipe Diameter
The diameter of the HDPE pipe is another crucial factor that affects its PSI rating. Larger diameter pipes generally have higher PSI ratings, as they have more material and surface area to withstand pressure. Smaller diameter pipes may have lower PSI ratings and are suitable for applications that involve lower pressure levels.
Wall Thickness
The wall thickness of an HDPE pipe also impacts its PSI rating. Thicker walls provide increased strength and resistance to pressure, allowing the pipe to handle higher PSI levels. Conversely, pipes with thinner walls may have lower PSI ratings and are suitable for applications with lower pressure requirements.
Working Temperature
The temperature at which the HDPE pipe will operate is an important consideration when determining its PSI rating. High temperatures can affect the material properties of the pipe, potentially reducing its ability to withstand pressure. It is essential to consider the maximum operating temperature of the pipe and choose a PSI rating that can handle the expected temperature range.
The PSI rating of HDPE pipes is determined through rigorous testing and certification processes. Understanding how these ratings are determined will provide you with confidence in the accuracy and reliability of the chosen pipe.
Testing Standards
There are industry standards and testing protocols in place to determine the PSI rating of HDPE pipes. Organizations such as the American Society for Testing and Materials (ASTM) and the International Organization for Standardization (ISO) have established specific tests to evaluate the performance and strength of HDPE pipes. These tests measure factors such as burst pressure, tensile strength, and long-term hydrostatic strength to determine the appropriate PSI rating.
Burst Pressure Testing
Burst pressure testing is one of the crucial tests conducted to determine the PSI rating of an HDPE pipe. This test involves subjecting the pipe to increasing internal pressure until it fails. The pressure at which the pipe bursts determines its maximum PSI rating, indicating the pressure it can withstand without failure.
Long-Term Hydrostatic Strength Testing
Long-term hydrostatic strength testing evaluates the pipe&#;s ability to withstand pressure over an extended period. This test involves subjecting the pipe to a constant pressure for an extended duration, simulating real-world conditions. The results of this test help determine the pipe&#;s long-term performance and its appropriate PSI rating.
Compliance and Certification
HDPE pipes that meet the required standards and pass the necessary tests receive certification indicating their PSI rating. It is crucial to choose pipes from reputable manufacturers who comply with industry standards and provide certified products. This ensures that the PSI rating of the pipe is accurate and reliable.
HDPE pipes are available in a range of PSI ratings to accommodate various applications and pressure requirements. Understanding the different PSI ratings and their applications will help you select the right pipe for your specific needs.
Low-Pressure Ratings
HDPE pipes with low-pressure ratings are suitable for applications that involve minimal pressure levels. These pipes typically have PSI ratings ranging from 50 to 100 PSI and are commonly used for irrigation systems, landscaping, and residential plumbing applications.
Medium-Pressure Ratings
Medium-pressure HDPE pipes are designed to handle moderate pressure levels. These pipes usually have PSI ratings ranging from 100 to 200 PSI and are commonly used in industrial processes, water distribution systems, and wastewater treatment plants.
High-Pressure Ratings
HDPE pipes with high-pressure ratings are engineered to handle demanding applications that involve high fluid or gas pressures. These pipes typically have PSI ratings ranging from 200 to 500 PSI or higher. They are commonly used in industries such as oil and gas, mining, and municipal water supply systems.
Extra-High-Pressure Ratings
For extreme pressure requirements, extra-high-pressure HDPE pipes with PSI ratings exceeding 500 are available. These pipes are designed to withstand heavy industrial applications, such as high-pressure water lines, compressed air systems, and hydraulic systems.
Choosing HDPE pipes with higher PSI ratings offers several advantages in terms of performance, durability, and safety.
Increased Durability
HDPE pipes with higher PSI ratings are inherently more durable and resistant to deformation under pressure. Choosing pipes with higher ratings ensures they can withstand unexpected pressure surges or external loads, reducing the risk of pipe failure and the need for frequent replacements.
Improved Resistance to Environmental Factors
HDPE pipes with higher PSI ratings often have enhanced resistance to environmental factors such as UV radiation, chemicals, and abrasion. These pipes are designed to withstand harsh conditions, making them suitable for outdoor applications and installations in corrosive environments.
Enhanced Safety
By choosing HDPE pipes with higher PSI ratings, you can ensure the safety of your system and personnel. These pipes are built to handle high-pressure situations, minimizing the risk of leaks, bursts, and other hazardous incidents that could endanger people or property.
Long-Term Cost Savings
Investing in HDPE pipes with higher PSI ratings may require a higher upfront cost, but it offers long-term cost savings. These pipes require less frequent maintenance, replacements, and repairs, leading to reduced downtime, lower operational costs, and improved overall system efficiency.
HDPE pipes with different PSI ratings find diverse applications across various industries and sectors. Understanding these applications allows you to choose the right pipe for your specific project.
Agricultural Irrigation
HDPE pipes with suitable PSI ratings are widely used in agricultural irrigation systems. They can efficiently transport water over long distances and withstand the pressure required for efficient irrigation of crops.
Water Supply Systems
HDPE pipes with different PSI ratings are commonly used in water supply systems, catering to both residential and commercial needs. These pipes ensure the safe and efficient distribution of potable water from the source to the consumer.
Gas Distribution Networks
HDPE pipes with appropriate PSI ratings are widely used in gas distribution networks. They can safely transport natural gas or other gases from the source to residential, commercial, and industrial areas, ensuring reliable and efficient gas supply.
Sewage and Drainage Systems
HDPE pipes with suitable PSI ratings are utilized in sewage and drainage systems to transport wastewater and stormwater. These pipes can withstand the pressure and flow requirements of these systems, ensuring efficient and reliable drainage.
Mining Applications
HDPE pipes with higher PSI ratings are extensively used in mining applications. They can handle the high-pressure requirements of slurry transportation, mine dewatering, and other mining processes, providing a reliable and durable solution for the industry.
Industrial Processes
HDPE pipes with varying PSI ratings find applications in various industrial processes, such as chemical processing, manufacturing, and power generation. These pipes can handle the pressure requirements of these processes, ensuring the safe and efficient transportation of fluids.
Geothermal Systems
In geothermal systems, HDPE pipes with suitable PSI ratings are used to transport hot water or steam from geothermal sources to power generation facilities or heating systems. These pipes can withstand the high temperatures and pressures associated with geothermal energy.
Landscaping and Sprinkler Systems
HDPE pipes with appropriate PSI ratings are commonly used in landscaping and sprinkler systems. They can handle the pressure required for efficient irrigation and watering of lawns, gardens, parks, and sports fields.
Industrial Chemical Transport
HDPE pipes with high PSI ratings are ideal for transporting various industrial chemicals. They can handle the pressure requirements and resist chemical corrosion, ensuring the safe and efficient transport of chemicals in industrial settings.
Municipal Water Distribution
HDPE pipes with different PSI ratings are extensively used in municipal water distribution systems. They can handle the pressure requirements of supplying water to residential and commercial areas, ensuring a reliable and constant water supply.
Proper installation is crucial to maximize the performance and longevity of HDPE pipes. Follow these guidelines when installing HDPE pipes with specific PSI ratings.
Trenching and Excavation
Before installing HDPE pipes, ensure proper trenching and excavation to provide a stable foundation. The trench should be wide enough to accommodate the pipe and allow for proper backfilling and compaction.
Jointing Methods
Choose the appropriate jointing method based on the PSI rating of the HDPE pipe. Common jointing methods include butt fusion, electrofusion, and mechanical couplings. Follow manufacturer guidelines and ensure proper alignment and welding for a secure and leak-free joint.
Fittings and Accessories
Select fittings and accessories that are compatible with the PSI rating of the HDPE pipe. Ensure proper installation and use of fittings, such as elbows, tees, and valves, to maintain the integrity and flow of the system.
Pressure Testing
After installation, perform pressure testing to ensure the integrity of the HDPE pipe system. Follow industry standards and guidelines to conduct the appropriate pressure tests, such as hydrostatic or pneumatic testing, to verify the system&#;s ability to handle the required pressure.
Backfilling and Compaction
Proper backfilling and compaction around the installed HDPE pipes are essential to provide stability and protect the pipes from external loads. Follow recommended practices for backfilling and compaction to prevent damage to the pipe and maintain its performance.
Protection and Marking
Protect the installed HDPE pipes from potential damage by providing appropriate markings, warning tapes, or protective covers. This ensures easy identification and prevents accidental damage during future excavation or construction activities.
Regular maintenance and proper care are crucial to ensure the longevity and optimal performance of HDPE pipes.
Inspections
Regularly inspect HDPE pipes for signs of damage, leaks, or degradation. Perform visual inspections, and if necessary, use non-destructive testing methods to identify any potential issues that may compromise the pipe&#;s performance.
Cleaning and Flushing
Periodically clean and flush HDPE pipes to remove any debris, sediment, or scale buildup that may affect the flow or pressure. Use appropriate cleaning methods and equipment to maintain the pipes&#; efficiency.
Repair and Replacement
In the event of damage or failure, promptly repair or replace the affected section of HDPE pipe. Follow manufacturer guidelines and seek professional assistance if needed to ensure proper repair and maintain the system&#;s integrity.
Preventive Measures
Implement preventive measures to avoid potential issues and prolong the lifespan of HDPE pipes. This may include protecting pipes from extreme temperatures, avoiding exposure to chemicals or corrosive substances, and implementing proper support and anchoring to prevent sagging or movement.
Here are answers to some frequently asked questions related to HDPE pipe PSI ratings:
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What is the maximum PSI rating for HDPE pipes?
The maximum PSI rating for HDPE pipes can vary depending on factors such as diameter, wall thickness, and material composition. Higher-rated HDPE pipes can have PSI ratings exceeding 500 or even higher, depending on the specific application requirements.
Can I use a lower PSI-rated HDPE pipe for a higher-pressure application?
No, it is not recommended to use a lower PSI-rated HDPE pipe for a higher-pressure application. Doing so may lead to pipe failure, leaks, or other safety hazards. Always choose a pipe with a PSI rating that matches or exceeds the pressure requirements of your application.
Can HDPE pipes with different PSI ratings be connected together?
HDPE pipes with different PSI ratings should not be directly connected together. It is essential to use appropriate transition fittings or couplings to ensure a secure and leak-free connection between pipes with varying PSI ratings.
How can I verify the PSI rating of an HDPE pipe?
You can verify the PSI rating of an HDPE pipe by checking the manufacturer&#;s documentation and certification. Reputable manufacturers provide accurate and reliable information about the PSI rating of their pipes.
The HDPE pipe industry is constantly evolving, with ongoing advancements in technology and manufacturing techniques.
Enhanced Material Compositions
New material compositions are being developed to enhance the strength, durability, and performance of HDPE pipes. These advancements allow for higher PSI ratings and improved resistance to environmental factors.
Thinner Wall Technology
Innovations in manufacturing techniques enable the production of HDPE pipes with thinner walls while maintaining the required PSI ratings. Thinner wall pipes offer benefits such as improved flow rates, reduced transportation costs, and more efficient installations.
Improved Jointing Methods
New jointing methods and technologies are being developed to enhance the strength and integrity of HDPE pipe connections. These innovations provide more secure and reliable joints, reducing the risk of leaks or failures.
Smart Pipe Systems
Advancements in sensor technology and connectivity are leading to the development of smart pipe systems. These systems can monitor and provide real-time data on factors such as pressure, flow rate, temperature, and potential issues, allowing for proactive maintenance and optimization of HDPE pipe networks.
In conclusion, understanding the HDPE pipe PSI rating is essential for selecting the right pipe for your specific needs. By considering factors that influence the PSI rating, familiarizing yourself with different ratings and their applications, and following proper installation and maintenance guidelines, you can ensure the longevity and optimal performance of your HDPE pipes. Stay informed about the latest innovations in the industry to leverage the advancements that can further enhance your projects. With this comprehensive guide at your disposal, you are well-equipped to make informed decisions and achieve successful outcomes.
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Q. 13 Why is there a difference in pressure rating (PR) and working pressure rating (WPR) when comparing HDPE pipe and PVC pipe?
The term pressure rating (PR) refers to the static pressure rating of the pipe, calculated from the hydrostatic design basis (HDB) with an appropriate design factor (DF) and is for a pipeline with no flow. However, all municipal water systems involve flowing water. For example, HDPE (PE) DR 17 pipe has a static pressure rating for water of 125 psig. The working pressure rating (WPR) is based on actual system requirements and is a dynamic pressure rating, that is, a pressure rating for pipe with flowing water. The WPR includes an allowance for water hammer surge pressures. At a daily recurring average flow surge velocity of 5 fps and at 80oF, the working pressure rating of HDPE (PE) DR 17 pipe is also125 psig; similarly, the working pressure rating for PVC DR
18 is 120 psig per AWWA C900-07, Equation 4. As such, PE has a higher working pressure rating than PVC at these common conditions. A summary is shown below:
Also, based on AWWA C900-07, Example B.2 modified with 5 fps recurring surge velocity, the estimated number of cycles to failure for the DR18 PVC pipe is less than 1 million cycles and the Fatigue Life is about 20 years which is less than half of the 50 year Design Life that was required in the example; in addition, the assumed 55 cycles per day may not be adequate; assuming 1 surge cycle every 15 minutes (96 cycles per day) and the 5 fps recurring surge velocity results in a Fatigue Life of about 11 years. On the other hand, IGN 4-37-02, &#;Design Against Surge and Fatigue Conditions for Thermoplastic Pipes&#;, can be used to show that under the same conditions, an HDPE DR17 pipe has a fatigue life of 10,000,000 cycles or in excess of 100 years. This striking difference is due to HDPE&#;s toughness and fatigue resistance.
Q. 14 Where can I find engineering properties such as the modulus and tensile strength values for HDPE pipes?
Engineering data for HDPE pipes may be found in Chapter 3 of the PPI&#;s Handbook* of Polyethylene Pipe, 2nd ed.
Q. 15 Do I have to be concerned with the long-term effects of creep?
All plastic materials, including HDPE and PVC, are subject to creep. Proper design, such as using the long-term modulus of the material where appropriate, accounts for creep effects.
Q. 16 Is there a flow loss in HDPE pipe due to the inner bead resulting from the butt fusion process?
The fusion bead has very little effect on the flow as it is basically rounded and protrudes very
little on the inside surface of the pipe Secondly, the Hazen-Williams C-factor of 150 takes into account the inner bead. Field tests confirm that a 150 C- factor used in the Hazen- Williams equation properly calculates actual flow and that the bead is of no hydraulic significance for either pressure or flow. The Hazen-Williams Friction Factor, C, for PE pipe was determined in a hydraulics laboratory using heat fusion joined lengths of pipe with the inner bead present.
Q. 17 Will sunlight adversely affect HDPE pipe?
Sunlight is not a concern if black pipe is used. Carbon black, utilized in most all HDPE pipe is the most effective ultraviolet stabilizer and therefore, black is the recommended pipe color for exposed long term service or storage. Pipe of this color will provide decades of outdoor use similar to that of black power-line cable jacketing. HDPE pipe produced in nonblack colors may also be supplied for outdoor exposure (storage and use) but its life expectancy is much less and is usually specified for a particular time period. Questions on this topic should be referred to the pipe manufacturer.
Q. 18 What is the life expectancy of HDPE pipe in water applications?
Many installations of HDPE pipe in water applications are already reaching 50 years of successful service. The polyethylene pipe industry estimates a service life for HDPE pipe to conservatively be 50-100 years. This relates to savings in replacement costs for generations to come.
Q. 19 Will HDPE pipe float in water?
Yes, HDPE pipe, due to its density being slightly less than water, will float even when full of water. When it is desired to ensure flotation of the line, various forms of collars, saddles, and strap-on flotation devices are available. For underwater anchored pipeline installations, it is important to specify the proper weights and spacing of the weights. Screw-anchors are a practical alternative. Whenever possible, an underwater pipeline should be installed in a trench with protective crushed rock cover. Refer to Chapter 10 of the PPI Handbook of Polyethylene Pipe, 2nd ed.
Q. 20 What is the max-min temperature range across which HDPE pipe for water pressure applications may be used?
HDPE pipe&#;s typical operating temperature range is from -40oF (-400C) to 140oF (60oC) although some products may be pressure rated for service as high as 180oF (82oC). Since water freezes below 32oF (00C) the practical lower temperature limit for water is 32oF (0oC). Consult with the pipe producer for information on applications.
Q. 21 When using HDPE pipe, will the pipe deliver the same flow-rate as the modestly larger ID ductile-iron pipe with the same outside diameter?
The inside surface of HDPE pipe is devoid of any roughness which places it in the &#;smooth pipe&#; category, a category that results in the lowest resistance to fluid flow. For water applications, HDPE pipe&#;s Hazen and Williams C factor for design is 150 and does not change over time. In contrast, the C factor for iron pipe and other traditional piping products declines dramatically over time due to corrosion and tuberculation or biological build-&#;up. In view of these advantages, it is often possible to utilize HDPE pipe of smaller inside diameter than Ductile Iron pipe, and still achieve or exceed the project&#;s required flow parameters. A detailed examination of the flow computations is encouraged. For flow factors and hydraulic design equations refer to Chapter 6 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed.
Q. 22 What is the maximum water pressure rating for HDPE pipe?
The maximum rating depends on several factors, the material designation code from which the pipe is made, the DR of the pipe, and the design operating temperature of the application. Refer to the tables below for sample ratings and allowable pressures:
The following table gives the Pressure Class per AWWA C901-08, the Pressure Rating and Allowable Total Pressure During Surge for PE pipe at 80o F.
The following table gives the Pressure Class per AWWA C901-08 and AWWA C906-07, the
Pressure Rating and Allowable Total Pressure During for PE pipe at 80oF.
Q. 23 What is the safe peak pressure (surge plus pumping) for HDPE pipe?
AWWA C901 defines two types of surge pressure, recurring and occasional. The safe peak pressure or allowed total pressure for HDPE pipe is 1.5 times the pipe&#;s pressure rating for recurring surge, and 2.0 times the pipe&#;s pressure rating for occasional surge. For instance a DR 11 PE has a pressure rating of 200 psig at 80oF and can safely handle total pressure during recurring surge of 300 psig and total pressure during an occasional surge of 400 psig. Refer to the answer under Q. 22 for additional data.
Q. 24 What is the maximum flow velocity for HDPE Pipe?
In a pumped system the maximum operating velocity is limited by the surge pressure capacity of the pipe. The Plastics Pipe Institute&#;s Handbook of Polyethylene Pipe states that &#;if surge is not a consideration, water flow velocities exceeding 25 feet per second may be acceptable.&#;
Q. 25 How does surge pressure in HDPE pipe compare with DI or PVC pipe?
Surge pressures in HDPE pipe are significantly lower than in DI pipe and lower than PVC pipe due to the lower value of dynamic modulus for HDPE. For example, a velocity change of 5 fps would cause a 51 psig surge in HDPE DR 17 pipe, a 87 psig surge in PVC DR 18 pipe, and a 262 psig surge in DI Class 350 lined pipe. Lower surge pressures often means longer life for pumps and valves in an HDPE pipeline, as well as lower pressure class pipes.
Q. 26 How does HDPE pipe&#;s capacity for recurring surge pressures (fatigue) compare to other pipes?
HDPE has exceptional capacity for handling recurring surge pressures. For example, in AWWA standards recurring surge pressure must be subtracted from PVC pipe&#;s Pressure Class whereas PE has resistance up to 150% of its Pressure Class. Marshall and Brogden report on the cyclical fatigue strength of PVC and HDPE and their report shows, at a cyclical stress range of 10 MPa ( psi) some PVC pipes failed at approximately 400,000 cycles whereas HDPE pipe reaches 10,000,000 million cycles before failure.
Q. 27 What are the safe maximum and minimum burial depths for HDPE pipe? Safe burial depths vary and should be calculated. In lieu of calculations, AWWA states that for an embedment soil with an E&#;of psi and no surface water, HDPE pipes with DR&#;s ranging from 7.3 to 21 can be safely buried from a depth of 2 ft to 25 ft where no traffic load is present and from 3 ft to 25 ft where H20 live load is present. However, most HDPE pipes can be buried to deeper depths, e.g. HDPE leachate collection pipe in landfills often have cover depths in excess of a hundred feet. Equations for calculating burial depth can be found in Chapter 6 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed.
Q. 28 Is HDPE pipe suitable for use under railroads?
While HDPE pipe is structurally capable of direct burial under railroads it is not recommended under a railroad mainline unless it is encased for safety reasons. In fact, many if not most railroad specifications require that pressurized pipes located beneath rail lines must be encased, and this requirement applies regardless of pipe material. However, uncased direct burial may be considered for use under rail lines located within plant yards.
Q. 29 Are thrust blocks required with HDPE pipelines?
No. HDPE pipe and fittings joined by heat fusion are self-restrained in all applications, and therefore do not require thrust blocks, provided the entire system is fused. Thrust blocks may be required in cases where special gasketed mechanical fittings are used. This may be necessary to prevent separation of the gasketed joint just as it is required for gasketed PVC and ductile iron pipe in pressure applications. Detailed discussion of this topic can be found in Chapter 9 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed. Publications available from the pipe manufacturer may also cover this subject.
Q. 30 Can pipe-bursting technology be used on ductile-iron and cast-iron pipes? Yes, pipe bursting has proven to be a very valuable means of pipeline rehabilitation. The pipeline rehabilitation industry has adopted &#;pipe bursting&#; as the name of the process of rupturing brittle pipes (e.g., cast iron, clay, etc). A variation employed for ductile materials (i.e., ductile iron, steel, etc.), is called &#;pipe splitting&#;, which uses cutters to achieve enlargement of the host pipe. Preparation of the host pipe to receive the HDPE pipe is accomplished with a cone shaped head in both bursting and splitting processes. Refer to PPI Handbook of Polyethylene Pipe, 2nd ed., Chp 16.
Q. 31 How does the impact strength of HDPE compare with other pipes?
HDPE is a ductile material and has exceptional impact strength. HDPE&#;s superior impact strength provides a piping system that is near impervious to impact damage and to damage from improper tapping. In the real world, engineers understand that pipes must be tough and resist impact and handling damage. HDPE pipes are field tested and proven to be impact tough.
Q. 32 Will the presence of hydrocarbons in soils in which HDPE pipe is buried affect the pipe or permeate through its wall into the water stream? AWWA has addressed concerns regarding hydrocarbon permeation by including a permeation statement in all of its pipe standards including standards for polyethylene (PE) (C901-08 p. 6, C906-07 p. 6), polyvinyl chloride (PVC) (C900-07 p. 6, C905-97 p. 3), steel (C200-05, p. 7), ductile Iron (C110-03, p. 3), and others. Hydrocarbons do not degrade polyethylene but can diffuse through the wall of HDPE pipe in areas of gross contamination. The exterior contact may affect saddle fusion connections, thus, after HDPE pipes have been exposed to grossly contaminated soils, mechanical connections may be preferred. In addition, while measures need to be taken to limit the impact of hydrocarbon permeation, the vast majority of HDPE water pipe installations will never be impacted by this problem. For more detailed discussion and information on this topic log on to: http://plasticpipe.org/pdf/ppi-comment-permeation-hydrocarbons.pdf
C. JOINING
Q. 33 How are HDPE pipe segments joined and connected?
HDPE pipe is easily and dependably joined using the standardized butt-fusion procedure. In this process matching ends of the pipes to be joined are aligned and heated with standard tools until the surfaces have become molten. When engaged under moderate pressure, the melt faces flow together forming a monolithic, homogeneous joint that, as the material cools, yields joints that are as strong as or stronger than the pipe itself.
There are several other well established heat fusion procedures used to join HDPE pipe such as electrofusion, which is exceptionally well suited for the assembly of pipe to fittings, or for making tie-ins or repairs, and saddle fusion which is used for the attachment of service fittings to HDPE mains. More details of some of these heat fusion procedures can be found in ASTM standards such as F, Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings, AWWA Manual M55, &#;PE Pipe &#; Design and Installation, and in Chapter 9 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed. In addition, most of the pipe / fittings producers publish literature covering their recommendations for heat fusion joining of their products.
Apart from the heat fusion process of joining HDPE pipe, it can also be joined successfully with a variety of mechanical style fittings. Details of these joining systems can also be found in Chapter 9 of the Handbook mentioned above or by consulting directly with the pipe manufacturer.
Q. 34 How long does it take to make a butt fusion joint in HDPE pipe?
The time required to make a butt fusion joint is dependent upon the pipe wall thickness and diameter, and the field weather conditions. The thicker the pipe being joined the longer it takes to make a butt fusion joint, due to heating and cooling time requirements. An estimate on 6&#; DR11 pipe would be about 4 to 5 minutes to load the pipe, face it, heat it and apply the fusion force. An additional 5 to 6 minutes would be required to let the joint cool under pressure. A rough guide is to approximate 1-1/2 to 2 minutes per diameter-inch per joint. Alternatively, the use of certain other proven and validated industry fusion technologies may shorten the cooling time
Q. 35 Can HDPE pipe be fused and installed in sub-zero weather conditions?
Yes, but the operator and fusion machine must be protected from the, wind, moisture or blowing snow so that the heater plate uniformly heats the ends of the pipes. Please refer to the pipe manufacturer&#;s recommendations for fusing and installing HDPE pipe under these conditions or the cold weather guidance in ASTM F , Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings. For situations in which weather conditions prohibit fusion joining, mechanical connections should be considered.
Q. 36 What inspection criteria are used to assure quality heat-fusion joints?
First, insure the fusion joint is made in accordance with PPI and/or the pipe/fitting manufacturer&#;s fusion procedure guidelines. This could be accomplished by recording either manually or by an electronic data logging device the critical parameters of each fusion joint and by comparing this data to the approved standard to prevent an improperly fused joint from being buried in the ground. Second, the time proven method used for field inspection of fusion joints is visual examination of the melt bead. Many pipe manufacturers provide printed or video examples of melt beads illustrating quality and sub-standard heat-fusion joints. . Refer to ASTM F, Standard Practice for Heat Fusion Joining of Polyethylene Pipe and Fittings.
Q. 37 Should the butt fusion bead be removed from an HDPE pipe joint?
Refer to Chapter 9 of the PPI PE Handbook.
Q. 38 Is extensive training required to operate a fusion machine?
Most people can be trained quickly to properly fuse HDPE pipe; for assistance, refer to PPI TN42, Recommended Minimum Training Guidelines for PE Pipe Butt Fusion Training Operators for Municipal and Industrial Projects.
Q. 39 How do heat fusion operators become qualified (or trained)?
Some pipe manufacturers and authorized distributors of pipe, fittings and fusion equipment conduct training and operator qualification programs year round, both on-site and at their facilities. Details of a suggested training program are outlined in a PPI publication TN42, entitled, &#;Recommended Minimum Training Guidelines for PE Pipe Butt Fusion Training Operators for Municipal and Industrial Projects.&#; The PPI or pipe manufacturer&#;s recommended fusion joining procedures must be followed to assure a quality joint is produced.
Q. 40 Where do I get the equipment to fuse HDPE pipes?
A list of the of fusion equipment manufacturers can be obtained by contacting PPI The HDPE pipe distributor or pipe manufacturer may also be able to supply information in answer to this question..
Q.41 Can HPDE service tubing be joined with mechanical couplings?
Yes, mechanical couplings are commonly used on HDPE sizes 2&#; and below and come in a variety of installation methods such as stab type or interference fit. To maintain homogenous, leak free, and corrosion resistant HDPE service tubing systems, couplings molded from HDPE resins are preferred versus metallic (brass) couplings. Mechanical couplings molded from HDPE can offer significant excavation and labor cost savings and in general, require very little training and tooling to install. These service tubing fittings provide joints with the same integrity and life expectancy as fusion; however, some mechanical joints require the use of restraint devices, while other mechanical coupling products include stiffeners to prevent pullout of the final joint. Additional detail on the form and function of these products is available in the PPI Handbook 2nd ed., Chapters 9 and 15. Also, refer to PPI Technical Note TN22, PPI Guidelines for Qualification Testing of Mechanical Couplings for PE Pipes in Pressurized Water or Sewer Service.
Q. 42 Are gaskets required between the faces of HDPE flange adapters?
Generally it is not recommended or necessary that a gasket be used when making connections that involve two mating HDPE flanges for water pressure applications operating at 80 psi or less. However, special tightening of the bolting system is required and that may include re-tightening of the bolts in 4-hours to 24-hours after the initial torque. PPI publishes a technical note, TN 38 that deals with this subject in considerable detail and with other options for flanged connections made between HDPE and other pipe materials. It is strongly recommended that the design engineer/contractor refer to this document when faced with issues of design or assembly of any flanged connection involving HDPE pipe.
Q. 43 How is HDPE pipe connected and joined to PVC pipe?
Methods of joining HDPE pipe to PVC pipe vary with the size and style of PVC. Common methods include slip-joint anchor fittings, gasketed joint adapters, and flange connections. HDPE to PVC transition fittings are also available from certain fittings manufacturers; also, refer to PPI TN-36, General Guidelines for Connecting HDPE Potable Water Pressure Pipes to DI and PVC Piping Systems, for additional information.
Q. 44 How can HDPE pipe be connected to other pipe products such as ductile iron pipe or valves?
For pressure applications, HDPE transition fittings, HDPE mechanical-joint adapters, gasket-joint adaptors, HDPE flanges, and standard metal couplings with internal stiffeners are recommended. The most common method is to use an HDPE MJ (mechanical joint) adapter to connect the HDPE pipe end in a DI MJ bell using the bolt and gland kit supplied by the HDPE MJ manufacturer. DIPS sized HDPE pipe may be inserted directly into an MJ bell with a restraint ring and insert stiffener for the HDPE pipe. When joining HDPE pipe to a DI pipeline either the DI joints must be restrained or the transition connection must be anchored. More details of these mechanical joining systems can be found in Chapter 9 of PPI&#;s Handbook* of Polyethylene Pipe, 2nd ed. and PPI TN-36, General Guidelines for Connecting HDPE Potable Water Pressure Pipes to DI and PVC Piping Systems. Information on these systems may also be obtained from the pipe manufacturer.
Q. 45 Can butterfly valves be used with flanged HDPE pipe?
Yes. In some cases, depending on the butterfly valve dimensions, butterfly valve flange adapters, or standard flange adapters with tapered ID spacers are required in order for the valve to open & close freely. Consult with your flange adaptor or mechanical-joint adaptor supplier to insure dimensional compliance.
Q. 46 What is the recommended practice for joining HDPE pipe to mechanical joint valves and fittings?
An HDPE mechanical joint (MJ) adapter is fused to the HDPE pipe. The HDPE MJ adaptor is inserted into the metal MJ bell, with the standard gasket in place. The bolts through the gland are evenly tightened in a star pattern to complete the MJ connection.
Q. 47 What HDPE fittings are available for HDPE pipe?
Fittings are available in sizes from ½&#; to 65&#;. Molded elbows, tees and concentric reducers are standard up to 12&#;. Fabricated fittings that include elbows, equal tees, reducing tees, laterals, crosses, concentric reducers, and eccentric reducers are usually stocked up to 24&#;. Fabricated fittings up to 65&#; that include elbows, equal tees, reducing tees, laterals, crosses, concentric reducers, and eccentric reducers are available by custom fabrication. Flanges, mechanical-joint adapters, outlet branch saddles, pull heads, gasket joint adapters, MIPT, FIPT and Weld End connections are available in most sizes.
Q. 48 Are there HDPE valves available?
Yes, there are several manufacturers offering HDPE valves; at present, 16&#; is the largest size available for water applications.
Q. 49 Are stiffeners recommended for Mechanical-Joint (MJ) Adapters?
Yes, several manufacturers recommend stiffeners for all diameters; other manufacturers offer MJ adapters with stiffeners for diameters 12&#; and larger. For diameters above 12&#;, seasonal thermal contraction and creep under radial gasket pressure can decrease the nose diameter of the MJ adapter. But while the gasket thickness is the same for 4&#; to 24&#; pipe diameters, the reduction in the nose diameter of the adapter caused by a drop in temperature becomes larger with increase in diameters. As a result, there is a greater loss of compression (and sealing capacity) of the rubber gasket in the larger sizes. Hence, stiffeners are recommended in larger diameters above 12&#;. More information on this subject as well as results of various tests is available in PPI&#;s technical note TN22, PPI Guidelines for Qualification Testing of Mechanical Couplings for PE Pipes in Pressurized Water or Sewer Service, at www.plasticpipe.org. Consult with individual HDPE MJ adapter manufacturers for engineering information.
Q. 50 Will the existing municipal warehouse inventory of ductile iron fittings go to waste if I switch to an all HDPE piping system?
No. With the use of HDPE mechanical joint adapters, polyethylene pipe and ductile iron fittings are completely compatible. However, due to the flexibility and tighter bending radius that can be achieved with HDPE pipe, fewer fittings may be required.
Q. 51 How are service connections tapped onto HDPE pipe mains?
HDPE pipe can be cold or hot (under pressure) tapped using piping products presently available. Saddle fusion tapping tees, electrofusion tapping tees, electrofusion corp saddles, and branch-saddles are readily available. There are several bolt-on mechanical connections qualified for use with HDPE pipelines as well. With this variety of fittings, tapping is a straightforward procedure. More information on this topic is available in Chapter 9 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed.
Q. 52 Can a bolt-on tapping saddle/sleeve be used with HDPE pipe?
Generally speaking, many saddle manufacturers have saddles/sleeves specifically made for use with HDPE pipe and they are typically the same as those used with PVC pipe and sometimes the same as those used with Ductile Iron pipe. Service saddles often include double straps or extra wide straps and Belleville (spring) washers for use with HDPE pipe so that the tension on the strap remains constant once the nuts are properly torqued. As for tapping sleeves, some manufacturers such as JCM indicate that as long as it is a full sleeve in accordance with AWWA C110/111, it can be used on HDPE pipe.
Q. 53 Can HDPE pipe be direct threaded using the same tapping tools commonly used to tap PVC or ductile iron pipe?
No. Tapped threads are not recommended for use on HDPE piping products. The industry standards for service taps to HDPE mains recommend the use of saddle fusion tapping tees, electrofusion tapping tees, branch-saddles, and certain metal mechanical clamps.
Q. 54 Does HDPE pipe split in the same manner that can occur when PVC pipe is improperly tapped?
No. Due to the ductile nature of HDPE and the design of fittings used for tapping, no splitting will occur when properly &#;hot&#; tapping HDPE pipe.
Q. 55 Can HDPE pipe be joined by solvent coupling joints?
No. At this time, there are no known adhesives or solvent cements that are suitable for pressure sealing or that have sufficient strength characteristics to join HDPE pipes. Heat fusion, which includes butt fusion, electrofusion, saddle fusion and mechanical joints are the only methods for joining HDPE pipe.
D. INSTALLATION
Q. 56 How deep can HDPE pipe be installed?
Refer to the answer under question 27.
Q. 57 Are backfill procedures different for HDPE pipe vs. PVC pipe?
No. HDPE and PVC pipelines are installed using the same standard backfill procedures. Both are plastic materials requiring the same considerations for proper embedment and backfill. However, the particulars of the application may influence this somewhat. For example, very high DR (thinner wall) pipes installed under shallow cover that is subject to live loads may require a higher level of compaction of the embedment material than is required for pipes having lower DR&#;s i.e. stiffer pipe. Therefore, it is advisable to always follow the installation/backfill procedures recommended by the HDPE pipe producer or refer to Chapter 7 on underground installation of PE pipe in PPI&#;s Handbook of Polyethylene Pipe, 2nd ed.
Q. 58 Does HDPE pipe require cathodic protection? Can it be installed in &#;hot&#; soils that attack metal pipe?
HDPE pipe does not undergo galvanic corrosion and therefore it may be safely installed in hot soils that would attack metal pipes and there is no need for cathodic protection.
Q. 59 Are thrust blocks required with buried pressurized HDPE pipe?
Refer to the answer under question 29.
Q. 60 What is the allowable bending radius of HDPE pipe? How does it compare to PVC pipe?
HDPE pipes can safely be bent to a tighter radius than PVC; for the same size pipe, the HDPE pipe radius is about 1/10th the radius of PVC pipe. HDPE can be cold bent to the dimensions shown below for a long term application based on the pipe DR. Also, HDPE pipes may be bent to a tighter radius for a short term application, such as during installation.
Q. 61 How are HDPE pipelines located?
A tracer wire should be buried above the HDPE pipe at the time of installation to facilitate future location. If no metal wire was installed above the plastic pipe, ground-penetrating radar or acoustical resonance may be used.
Q. 62 What are the recommended procedures to pressure test a HDPE pipeline?
HDPE pipe should be pressure tested in accordance with PPI recommendations, (NOTE: other bell and spigot pipes are tested differently than HDPE &#; i.e. allowable leakage rates of bell and spigot versus expansion of PE ) For detailed information on this subject, refer to Chapter 2 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed. and to ASTM F, Standard Practice for Field Leak Testing of Polyethylene (PE) Pressure Piping Systems Using Hydrostatic Pressure
Q. 63 Compared to the host pipeline, when sliplining, what diameter HDPE pipe should be specified?
As a general or comfortable rule of thumb in sliplining applications involving sizes up to 24inches the outside diameter of the HDPE liner pipe should be about 90 percent of the inside diameter of the existing host pipe. For larger sizes the inside diameter of the host pipe should be about 2-inches greater than the outside diameter of the HDPE liner pipe, but this depends upon many factors including deflection, sag, bends, obstructions etc in the host pipe.. Therefore, it is advised that the design engineer refer to Chapter 11 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed. which covers &#;Pipeline Rehabilitation by Sliplining with PE Pipe.&#;
Q. 64 In sliplining and pipe bursting applications, is there another way to stop the tracking of ground water at the manhole, other than he use of chemical grout?
Yes. When HDPE pipe enters or exits a manhole it is best to use a link-seal or a water stop (also referred to as a puddle flange) with sealing grout. The link-seal or water stop will prevent water from seeping between the pipe and grout.
Q. 65 Must the entire annular space be grouted when sliplining with HDPE pipe for a water pressure application?
This depends on several factors such as a comparison of the applied internal operating pressure versus the external pressure from possible external loads, including earth loading, hydrostatic loading and superimposed loading. But while grouting of the termination points of internally pressurized systems is usual, grouting of the entire annular space is not often required. Irrespective, it is strongly recommended that the design engineer conduct an analysis of the project before deciding on the approach to this issue. For more details the reader is referred to Chapters 6 and 11 of PPI&#;s Handbook of Polyethylene Pipe, 2nd ed.
Q. 66 Are there any guidelines for the maximum length of HDPE pipe that can be pulled along the surface after fusing sections together?
The goal is, of course, to keep tensile stress in the pipe within allowable values for the pipe type and conditions. Maximum pulling length is a function of the tensile strength and weight of the polyethylene pipe, the temperature at which the pipe will be manipulated, the physical dimensions of the pipe, and the frictional drag along the length of the polyethylene pipe. Pipe rollers are available to reduce the friction between the pipe and the ground and allow longer lengths to be pulled. Equations 8 and 9 from Chapter 11, &#;Pipeline Rehabilitation by Sliplining with PE Pipe&#; of PPI&#;s Handbook of Polyethylene Pipe, are generally accepted for determination of the maximum feasible pulling length. One of the important factors in these calculations is the tensile strength of the particular polyethylene pipe product, which must be obtained from the manufacturer&#;s literature.
E. Maintenance & Repairs
Q. 67 When water freezes solid in an HDPE pipeline, will it damage the pipe? How is it most effectively thawed?
When water freezes solid in a HDPE pipe, it will not rupture it, but the pipe will expand with the ice. Obviously, the application of heat to the frozen section is really the only practical way to thaw it. But for safety considerations, and to avoid damage to the pipe, this must be done very carefully. One method is heat tracing. This involves wrapping the affected area with pressure sensitive metallic tape over which is wrapped temperature limited (120oF maximum) heat tracing tape. The metallic tape helps distribute heat evenly over the pipe surface. Heat blankets are also available, however torches or arc welders should not be used to thaw HDPE pipe. Consult the pipe manufacturer for more details on this or other thawing procedures recommended for use with HDPE pipe.
Q. 68 What percentage of external surface scratching or scarring is allowable on HDPE pressure pipe?
Scarring to a maximum depth of 10% of the pressure pipe wall thickness is generally tolerable. In fact, AWWA M55 states that &#;minor scratches or scuffing will not impair serviceability&#;. It also states that &#;pipe with gouges or cuts in excess of 10 percent of the product wall thickness should not normally be used&#;.
Q. 69 Is it possible to puncture HDPE pipe; how is that repaired?
Generally, only small diameter HDPE pipes can be severed by excavation equipment. And while it is possible to puncture
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