GP-IT005/1 TECHNICAL - GPS PE Pipe Systems
GP-IT005/1TECHNICALGPSPE PIPE SYSTEMSInnovation in polyethylene pipe systems for water, gas and other applicationsInstallation andTechnical Guidelines
GPSPE PIPE SYSTEMSOur CompanyMarket OrientedCustomer FocusGPS PE Pipe Systems is a member ofthe international Aliaxis Group ofCompanies who manufacture and sellpipe systems and related products forresidential and commercial construction,industrial and public utilities.GPS PE Pipe Systems products have abroad range of applications in theindustrial and utilities markets on aworldwide basis. The utilities of waterand gas distribution are importantsectors for high integrity products wherethe maintenance of water quality andthe safe transport of gaseous fuels are ofparamount importance. Industrialapplications include: alternative energyinstallations in landfill gas systems;effluent transportation and mineralslurries.The key to our success lies in thecommitment we pledge to provide thehighest quality service and support toour customers and industry end-users.We are a team of highly motivated andexperienced individuals who arededicated to helping our customersachieve their goals.We specialise in the research,development and manufacture ofpolyethylene and multi-layer pipesystems including fittings for gas andwater transportation in the utilities,offshore and industrial markets.Resulting from the amalgamation oftwo market leading companies, GPS PEPipe Systems brings together over onehundred years of experience andknowledge in plastic pipe systems.The EnvironmentWe actively and consistently strive toreduce our impact on the environment.We have measured our performanceagainst various environmental indicatorssince 1997 and operated anenvironmental management systemaccredited to ISO 14001 since 1999.Our carbon footprint is independentlyverified under the Certified EmissionsMeasurement and Reduction Scheme(CEMARS).Many of the brands in the GPS portfoliohave a long record of innovation inmeeting the needs of the water and gasutilities. One of the foremost pioneers inpolyethylene pipe systems, GPS iscontinually improving and updating itsoffering to meet the ever growing needsof the distribution engineer, ensuringthey stay at the forefront of world gasand water distribution/treatmentsystems.We place the utmost importance inmeeting the needs of our customers,constantly evolving our extensive productportfolio to meet the ever changingdemands of the water and gas utilities,industrial and offshore markets.QualityDesigned, manufactured and suppliedunder a BS EN ISO 9001:2008accredited Quality Management System,GPS products comply with relevantnational, European and internationalproduct standards to ensure peace ofmind for our customers.Manufactured in the UK, our productsare sold to more than 60 countriesworldwide.Certificate No. FM 34819Certificate No. E 51385World leaders in the design, manufacture, marketing and sales of highperformance, high integrity plastic and composite piping systems.
ContentsPagesGPS PE Products Overview2-3Quality and Environmental Standards4-5Health and Safety6Material Properties & Compatibility7-9Pressure Ratings & Flow Characteristics10-15Design16-20Handling & Storage21-24Product Marking25Procedures & Techniques for PE Pipeline Installations26-30Electrofusion Jointing Procedures31-33Jointing Instructions for DuraFuse Electrofusion34-39 Jointing Instructions for FRIALEN Large Diameter Electrofusion Couplers40-42Jointing Procedures for DuraFuse Tapping Tees & Branching Saddles43-45Assembly & Operating Instructions for Friatop46-48Butt-Fusion Jointing Procedures49-54Flanged Connections55-56Duck Foot Bend AssemblyJointing Instructions for Protecta-LineJointing Instructions for Secura-Line5758-7071Push-Fast System72-73Pressure Testing74-77Repair Section including Squeeze-Off78-81Equipment and Training SuppliersIndex8283-841
Products OverviewGPS PE piping products offer all the major advantages of polyethylene allowingconsiderably lower installation and whole life costs when compared to traditionalpipeline materials: Lighter weight for reduced logistical costs and easier handlingGreat flexibilityHomogeneous fully welded system is possibleNo corrosion and excellent chemical resistanceNo anchor or thrust blocks needed (fully end load bearing)Smooth, non-porous bore for better flow capacityLong system life (typically 100 years - as per IGN 4-32-18) with minimummaintenanceManufactured to meet the exacting standards imposed by gas and water bodies,polyethylene pipe systems from GPS offer: High quality - designed, manufactured and supplied under a BS EN ISO 9001: 2008accredited Quality Management System Wide choice of systems Up to 16bar rated at 20ºC when carrying water and certain other liquids Up to 10 bar (7 bar in the UK) rated at 20ºC when carrying natural gas Ease of use Four jointing methods - Electrofusion, Butt-fusion, Mechanical Fittings and Push-Fast(a mechanical integrated spigot and socket system) Full compliance with water & gas industry standardsStandard PE PipesGPS PE pipes are extruded in two standard materials - PE80 (MDPE) and Excel (PE100)in the following colours: Blue - for potable water supply below ground. Yellow/Orange - for gas supply below ground. Black - for global water and gas supplies, UK potable water supplies above the groundand industrial (sewage, mining and quarry) applications above and below ground.Pipes are available in 6m and 12m straight lengths with other lengths available to order.Pipe up to 180mm OD is also available in coils of 50m, 100m and 150m and may besupplied in longer lengths by special order. Pipe can also be extruded with four co-axialstripes to identify the contents being conveyed or to identify the application.Excel 3cExcel 3c is a unique patented factory clean PE100 pipe coil that is approved by theSecretary of State for installation without pre-chlorination. It allows installers to proceed toimmediate installation, significantly reducing the overall installation time and costs. Excel3c pipe may also be supplied complete with a factory fitted Towing Head, ready to beattached to a towing shackle for immediate installation, saving even more time.Protecta-LineProtecta-Line is an award winning fully integrated barrier pipe and fittings system for safelytransporting water through contaminated land. With WRAS and Regulation 31/27approvals, the system provides total peace of mind to the highest industry standardsincluding the new WIS 4-32-19, meeting all the safety legislation demanded by watercompanies and customers alike.Protecta-Line combines all of the advantages of conventional high quality PE pipe with analuminium barrier layer to prevent permeation of ground contaminants and an additionalPE outer protection layer. The Protecta-Line system is currently offered in pipe diametersfrom 25mm through to 355mm and incorporates a dedicated range of approved fittings: From 25mm to 63mm, a full range of Mechanical Compression Fittings requiringno scraping From 63mm to 180mm, a full range of Fluid Compression Fittings requiring no scraping From 90mm to 355mm, a full dedicated range of tapping ferrule off-takes with 25mm,32mm and 63mm Mechanical Compression Fitting outlets From 90mm to 355mm, a dedicated range of electrofusion fittings. Sizes 90mm to355mm of Protecta-Line can be also joined using butt-fusion.2GPSPE PIPE SYSTEMSTel: 44 (0)1480 52121Fax: 44 (0)1480 458829 Technical Support: 44 (0)1480 442620
Secura-LineSecura-Line is Excel (PE100) pipe with an outer protective skin of peelablepolypropylene, which provides extraordinary resistance to abrasion damage when usedin techniques such as pipe bursting. Secura-Line pipe also gives significant benefits andcost savings for installers: the outer polypropylene skin may quickly and easily beremoved to expose the perfect surface finish for jointing. The peeled pipe isimmediately ready for electrofusion or butt-fusion without any additional requirementfor scraping or cleaning. Secura-Line can be electrofused or butt-fused using the sameparameters as standard PE pipe.DuraFuse & Frialen Electrofusion FittingsDuraFuse electrofusion fittings are easy to use, offer superb performance and a rapid,convenient means of joining polyethylene pipes. Their design ensures optimum meltpressure because the energising coils of wire are precisely positioned to ensureuniformly consistent melting and to minimise the risk of accidental wire damage.Each fitting is bar coded to enable suitable electrofusion control units (ECUs) to scanthe bar code in order to determine the fusion parameters. DuraFuse fittings are offeredin PE80 (MDPE) Yellow or PE100 (HPPE) Black and in pipe sizes up to 500mm. GPSalso offers a range of larger diameter electrofusion fittings. The FRIALEN range isoffered in Black PE100 with bar code labelling to facilitate fusion and data logging.Long Spigot & Pupped FittingsThe GPS Long Spigot range offers a comprehensive choice of fittings suitable forbutt-fusion without the need for pupping (provided that machines with narrow clampsare used). Products are offered in PE80 Yellow, as well as PE100 Blue and Black. Tofacilitate easier jointing on-site, a range of fittings is also offered with factory-fitted halfmetre pups in pipe sizes up to 400mm and with one-metre pups for larger pipe sizes.GPS recommend derating the pressure rating of large diameter mitred bends in sizes355mm and above to 0.8 x the pipe rating from which they are made. Bendsincorporating 30 mitres should also be de-rated in sizes below 355mm.SlimFlangeSlimFlange is a unique product developed by GPS to allow size-for-size connection ofPE pipeline to metal fittings or pipe without any change to the nominal bore.SlimFlange features a steel reinforced PE face which allows the PE shoulder height tobe reduced significantly, while at the same time the strength of the joint is actuallyincreased and is fully end-load bearing. SlimFlange offers reduced weight, maintainsfull-bore flow and offers considerable cost savings. SlimFlange is made from PE100Black, comes complete with gasket and backing ring and may be pupped with all ofthe GPS pipe materials.Push-FastThe Push-Fast spigot and socket type jointing system has proven end load performance.Push-Fast enables fast, simple and efficient pipe jointing, without the need for weldingand is unaffected by weather conditions. Unlike similar spigot and socket systemsoffered in other materials, Push-Fast resists the end thrust generated by the internalpressure, so anchors or thrust blocks are not usually required. The Push-Fast systemhas individual elastomeric sealing and internal grip rings, ready chamfered pipe endsand is offered in Blue or Black Excel (PE100) rated up to 16 bar. This product is notsuitable for gas applications.GPSPE PIPE SYSTEMSWebsite: www.gpsuk.comEmail: enquiries@gpsuk.comGP-IT005/1 November 20113
QualityEnvironmentGPS operates a quality assurance system in accordancewith the requirements of BS EN ISO 9001, which isaudited on a regular basis by BSI.The quality assurance system imposes stringent standardsof control throughout design, development andsubsequent manufacturing and inspection processes.Products are subjected to a range of dimensional,mechanical and destructive tests carried out on a samplebasis in accordance with the requirements of GPS ProductQuality Plans. Upon agreement, these Quality Plans canbe amended to incorporate specific Customer Inspectionand Test requirements.Detailed records are kept of dimensional and performancetests for each production batch. Each batch is given aunique identification number that is reproduced on everyfitting and pipe. This enables traceability to be maintainedfrom raw material to finished products and for theprovision of Certificates of Conformity, if required.GPS operates an environmental management system inaccordance with the requirements of BS EN ISO 14001.The system is regularly audited by SGS to ensureconformance to the standard.GPS continually monitors its business activities with theaim of minimising their impact on the environment. Anumber of on-going waste minimisation projects havebeen implemented in areas such as energy usage, productpackaging and landfill waste.A continual improvement culture is promoted within thecompany by setting environmental targets and objectivesthat are regularly monitored and reviewed.Certificate No. FM 34819Certificate No. E 51385GPS polyethylene range is designed to comply with the requirements of one or more of the standards, specifications and guidance notes shown on this page.General StandardsStandardTitleApplicable to GPS ProductsISO 161-1:1996Thermoplastic pipes - nominal outside diameters and nominal pressuresAll pipes and fittingsISO 4065:1996Thermoplastic pipes - universal wall thickness tablesAll pipesBS ISO 11922-1:1997Thermoplastic pipes for the conveyance of fluids dimensions and tolerances metric series All pipesBS EN 1092-1:2007Flanges and their joints - circular flanges for pipes, valves, fittings and accessories,PN designatedAll flange backing ring drillings,PN16 and PN10Water Standards4Standard/ApprovalTitleApplicable to GPS ProductsRegulation 31 (England & Wales),Regulation 27 (Scotland),Regulation 30 (NI)The Water Supply (Water Quality) Regulations 2000 - EnglandThe Water Supply (Water Quality) Regulations 2001 - WalesThe Water Supply (Water Quality) Regulations 2001 - ScotlandThe Water Supply (Water Quality) Regulations 2007 - Northern IrelandAll pipesThe (Water) RegulatorsSpecification & The Water Supply(Water Fittings) Regulations 1999The (Water) Regulators Specification & The Water Supply (Water Fittings)Regulations 1999All pipe materials. All fitting materials.All PE100 fittings and matching pipes.All Protecta-Line fittings and matching pipesBS 6920 Part 1:2000Suitability of non-metallic products for use in contact with water intended for humanconsumption with regard to their effect on water - Part 1: SpecificationAll pipe materials. All fitting materials.All PE100 fittings and matching pipes.All Protecta-Line fittings and matching pipesBS 6920 Part 2:2008Suitability of non-metallic products for use in contact with water intended for humanconsumption with regard to their effect on water - Part 2: Methods of testAll pipe materials. All fitting materials.All PE100 fittings and matching pipes.All Protecta-Line fittings and matching pipesISO 4427:2007PE pipes for water supplyBlue and black PE80 and PE100 pipesand fittingsBS EN 15494:2003Specifications for polyethylene components and systemsBlue and black PE80 and PE100 pipes andfittings up to 1600 mmBS EN 12201:2003Plastic piping systems for water supply – polyethyleneBlue and black PE80 and PE100 pipes andfittings in sizes up to 1600 mmBS EN 805:2000Water supply – requirements for systems and components outside buildingsExternal water supply installationsBS EN 681-2:2000Elastomeric seals. Material requirements for pipe joint seals used in water anddrainage applications. Thermoplastic elastomers.Seals and flange gasketsBS 5306:1990 - Part 2Fire extinguishing installations and equipment on premisesBlue and black PE80 and PE100 for externalburied fire mainsBS 6572:1985Specification for blue polyethylene pipes up to nominal size 63mm for below grounduse for potable waterBlue PE80 pipes up to and including 63mmGPSPE PIPE SYSTEMSTel: 44 (0)1480 52121Fax: 44 (0)1480 458829 Technical Support: 44 (0)1480 442620
Water StandardsStandard/ApprovalTitleApplicable to GPS ProductsWIS 4-08-02:1994Specification for bedding and sidefill materials for buried pipelinesBackfill materials specificationWIS 4-22-02Specification for ferrules and ferrule straps for underground useProtecta-Line ferrulesWIS 4-24-01:1998Specification for mechanical fittings and joints including flanges for polyethylenepipes for the conveyance of cold potable water for the size range 90 to 1000including those made of metal or plastics or a combination of bothStub flanges, Slimflange and fluid compressionfittings in sizes 90mm to 1000mmWIS 4-32-08:2002Specification for the fusion jointing of polyethylene pressure pipeline systemsusing PE80 and PE100 materialsButt fusion and electrofusion jointing of blueand black PE80 and PE100 pipes and fittingsWIS 4-32-16:1998Specification for butt fusion jointing machinesAutomatic, semi automatic and manual buttfusion machinesWIS 4-32-17:2001- Issue 2Polyethylene pressure pipes for pressurised water supply and sewerage dutiesBlue and black PE80 and PE100 pipesincluding Securaline in sizes up to andincluding 1600mmWIS 4-32-19:2007Polyethylene pressure pipe systems with an aluminium barrier layer for potablewater supply in contaminated land sizes25mm to 630mm – Protecta-Line pipe andfittingsIGN 4-08-01:1994Bedding and sidefill materials for buried pipelinesBackfill materials selectionIGN 4-32-18:2003The choice of pressure ratings for polyethylene pipe systems for water supply andsewerage dutiesBlue and black PE80 and PE100 pipe systemsIGN 4-37-02:1999Design against surge and fatigue conditions for thermoplastic pipes blue and blackPE80 and PE100 pipe systemsIGN 9-04-03:2002The selection of materials for water supply pipes in contaminated landProtecta-Line pipes and fittingsDIN 8074:1999Pipes of high density polyethylene (HDPE) type 2 – dimensionsBlack PE80 and PE100 pipes in sizes up toand including 1600 mmDIN 8075:1999Pipes of high density polyethylene (HDPE) type 2 – testingBlack PE80 and PE100 pipes in sizes up toand including 1600 mmDIN 16963:1980Part 1 – High density polyethylene (HDPE) fittings dimensions, type 2Black PE80 and PE100 spigot and electrofusionfittings up to and including 1200mmGas StandardsStandardTitleApplicable to GPS ProductsISO 4437:2007Buried pipes for the supply of gaseous fuelsAll yellow and black pipes and electrofusion andspigot fittingsBS ISO 8085-1Polyethylene fittings for use with polyethylene pipes for the supply of gaseous fuelsAll yellow and black electrofusion fittings up toand including 630mmBS ISO 8085-2Spigot fittings for butt fusion or socket fusion using heated tools and for the use withelectrofusion fittingsAll yellow and black spigot fittings up to andincluding 630mmBS ISO 8085-3Electrofusion fittingsAll yellow and black electrofusion fittings up toand including 630mmBS EN 682:2002Elastomeric seals – materials for seals used in pipes and fittings carrying gas andhydrocarbon fluidsSeals and flange gasketsBS EN 1555:2010Plastic piping systems for supply of gaseous fuelsAll yellow PE80 and black PE100 pipes andfittings up to and including 630mmBS EN 12007-1:2000Gas supply systems – pipelines for maximum operating pressure up to andincluding 16 barPipeline recommendationsBS 2494GSpecification for elastomeric materials used in the manufacture of seals for gasmains and fittings up to 7 bar (BS EN 682)Seals and flange gasketsGIS/PL2:2006Specification for polyethylene pipe and fittings for natural gas and suitablemanufactured gasYellow PE80 and Secura-Line pipes up to 630mmPart 1General and polyethylene compounds for use in polyethylene pipe and fittingsRaw materialsPart 2Pipes for use at pressures up to 5.5 barYellow PE80 and Secura-Line pipes up to 630mmPart 4Fusion fittings with integral heating elementsYellow PE80 and orange PE100 and black PE100electrofusion fittingsPart 6Spigot end fittings for electrofusion and/or butt fusion purposesYellow PE80 and orange PE100 and black PE100spigot fittingsPart 8Pipes for use at pressures up to 7 barOrange PE100 pipes up to 500mmGIS/PL3:2006Specification for self anchoring mechanical fittings/joints for polyethylene(PE) pipe fornatural gas and suitable manufactured gasStub flanges and SlimflangeGIS ECE1Specification for electrofusion control unitsElectrofusion control boxesGIS/EFV1:2000Specification for flow limiters for PE services operating at pressures above 75 mbarand not exceeding 6m3/hrExcess flow limiters – electrofusion couplersand reducersGIS/F2Mains sealing plugs and service connec
TECHNICAL GP-IT005/1 Installation and Technical Guidelines GPS PE PIPE SYSTEMS. Our Company GPS PE Pipe Systems is a member of the international Aliaxis Group of Companies who manufacture and sell pipe systems and related products for . GP-IT005/1 GPS PE PIPE SYSTEMS. 2) GPS
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GPS outages. To overcome these limitations, GPS can be integrated with a relatively environment-independent system, the inertial navigation system (INS). Currently, most integrated GPS/INS systems are based on differential GPS (DGPS) due to the high accuracy of differential mode (Petovello, 2003 and Nassar, 2003). More recently, GPS-
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This plan is published by the GPS Directorate in accordance with the GPS Systems Engineering Plan (SEP) and is intended for use by GPS programs to conduct configuration management as required by Air Force Instruction (AFI) 63-101/20-101, Integrated Life Cycle Management. . SMC/GPE - System Engineering Division SMC/GPG - GPS .
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Reading GPS Time Series Plots Worksheet The Global Positioning System, GPS, is used to study the Earth, how tectonic plates move and how the Earth’s tectonic plates deform. GPS monuments are attached the ground and measure how the earth moves. While the GPS units in a car measure movement in miles per hour, high-
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