For BIS Use Only

Doc: CED 50 (12111)

January 2020

DRAFT FOR COMMENTS ONLY

(Not to be reproduced without the permission of BIS or used as an Indian Standard)

Plastic Piping System Last date of Comments:
Sectional Committee, CED 50 12 March 2020

Draft Indian Standard

MULTILAYER (PE-AL-PE) PLASTICS PIPING SYSTEMS FOR INDOOR GAS

INSTALLATIONS WITH A MAXIMUM OPERATING PRESSURE
UP TO AND INCLUDING 500 KPA (5 BAR) ― SPECIFICATION

FORWORD

(Formal clauses to be added later)

This Indian Standard has been formulated to cover requirements for multilayer (PE-AL-PE)
plastics piping systems for indoor gas installations with a maximum operating pressure up to
and including 500 KPa (5 bar).

In the preparation of this standard, considerable assistance has been derived from ISO
17484-1:2014 ‘Plastics piping systems — Multilayer pipe systems for indoor gas installations
with a maximum operating pressure up to and including 5 bar (500 kPa) — Part 1:
Specifications for systems’, which was developed in response to worldwide demand for a
new specification for multilayer pipes for gas supply. In India also, due to our national focus
to develop smart cities across the country, a large demand is expected to emerge for the
installation of new gas networks of multilayer pipes for the transportation of domestic gas.
The multilayer PE-AL-PE composite pipe is composed of one metallic layer, tie layers of
polymeric adhesive and inner and outer layers of polyethylene. The inner and outer layers
are bonded to metallic layer which is welded aluminium tube, by polymeric adhesive during
extrusion process.

This standard covers the following categories of fuels to be transported as per ISO
13623:2017 ‘Petroleum and natural gas industries — Pipeline transportation systems’:

a) Category D – Gaseous fuels – Non-toxic, single phase natural gas; and

b) Category E – Gaseous fuels – Flammable and/or toxic fluids that are gases at ambient
temperature and atmospheric pressure conditions and are conveyed as gases and/or
liquids, like liquefied petroleum gas (LPG) vapour and natural gas (not otherwise
covered in category D) or liquefied petroleum gas.

1
The minimum value of service design co-efficient at 27 °C shall be considered as 2 for
conveyance of gaseous fuels.

In this standard, for the evaluation of PE compound, an additional type test for 10 000 h at
20 °C has been included. For aluminium material to be used for the manufacture of
multilayer pipes, aluminium grade 31200 as per IS 737:2008 ‘Wrought Aluminium and
Aluminium Alloy Sheet and Strip for General Engineering Purposes – Specification (fourth
revision)’ which is equivalent to ENAW 3003 grade of EN 573-3 ‘Aluminium and aluminium
alloys - Chemical composition and form of wrought products - Part 3: Chemical composition
and form of products’ as prescribed in ISO 17484-1:2014, has been specified.

Multilayer pipes are delivered generally as a complete system. Pipes, fittings, tools, etc are
mostly not compatible with components of other brands/make. All components in a system
are perfectly geared to one another when they are procured from the same manufacturer.
Further, in case of repair/maintenance, the consumer can ensure to procure
spares/accessories from the same source.

Connections of threaded transition fittings shall be as per IS 554:1999 ‘Pipe threads where
pressure-tight joints are made on the threads ― Dimensions, tolerances and designation
(fourth revision) (Adoption of ISO 7-1:1994)’.

In the formulation of this standard assistance has also been derived from ASTM F 1282-17
‘Standard specification for Polyethylene/Aluminum/Polyethylene (PE-AL-PE) composite
pressure pipe’. Provisions of IS 14885:2001 ‘Specification for polyethylene pipes for the
supply of gaseous fuels ― Specification’ have also been considered while preparing this
standard.

This standard also provides guidelines for the storage, handling and installation of PE-AL-PE
multilayer pipes and fittings in its Annex R.

This standard does not purport to address all the safety issues associated with the use of this
piping system. It is the responsibility of the user of this standard to establish appropriate
safety and health practices and determine the applicability of regulatory safety and health
practices in accordance with the applicability of regulatory limitations prior to use.

For the purpose of deciding whether a particular requirement of the standard is complied with
the final value observed or calculated, expressing the result of a test or analysis, shall be
rounded off in accordance with IS 2:1960 ‘Rules for rounding off numerical values (revised)’.
The number of significant places retained in the rounded off value should be the same as
that of the specified value in this standard.

2
For BIS Use Only
Doc: CED 50 (12111)
January 2020

DRAFT FOR COMMENTS ONLY

(Not to be reproduced without the permission of BIS or used as an Indian Standard)

Plastic Piping System Last date of Comments:
Sectional Committee, CED 50 12 March 2020

Draft Indian Standard

MULTILAYER (PE-AL-PE) PLASTICS PIPING SYSTEMS FOR INDOOR GAS

INSTALLATIONS WITH A MAXIMUM OPERATING PRESSURE
UP TO AND INCLUDING 500 KPA (5 BAR) ― SPECIFICATION

1 SCOPE

1.1 This standard specifies the general requirements and the performance requirements for
multilayer (PE-AL-PE) plastics piping systems based on pipes, fittings and their joints
intended to be used for gas supply within buildings, ranging from 14 mm to 75 mm outside
diameter. This standard applies to systems that operate at temperatures of −20 °C up to
+60 °C. For the purpose of this standard, adhesive layers are considered as thermoplastic
materials. This standard is applicable for piping systems used in buildings to supply gas with
a maximum operating pressure of up to and including 500 kPa (5 bar). This standard is
applicable for the conveyance of following fuels:

a) Non-toxic natural gas; and

b) Flammable and/or toxic fluids which are gaseous at ambient temperature and
atmospheric pressure conditions and are conveyed as gases and/or liquids.

1.2 This standard gives guidance for the design of piping systems consisting of multilayer
pipes based on thermoplastics, for which at least 60 percent of the wall thickness shall be
polymeric material. Polymeric materials intended for stress-designed layer (inner layer) shall
be polyethylene (PE). The outer layer shall also be polyethylene (PE), and the intermediate
layer shall be aluminium.

2 REFERENCES

The standards listed below contain provisions which through reference in this text, constitute
provision of this standard. At the time of publication, the editions indicated were valid. All
standards are subjected to revision and parties to agreements based on this standard are
encouraged to investigate the possibility of applying most recent editions of the standards
indicated below:

3
 IS No. Title
Pipe threads where pressure-tight joints are made on the threads ―
554:1999
Dimensions, tolerances and designation (fourth revision)
wrought aluminium and aluminium alloy sheet and strip for general
737 : 2008
engineering purposes ― Specification (fourth revision)

Methods of test for polyethylene moulding materials and polyethylene

2530 : 1963
compounds
Random sampling and randomization procedures (first revision)
4905 : 2015
Polyethylene pipes for water supply ― Specification (fifth revision)
4984 : 2016
High density polyethylene materials for moulding and extrusion (first
7328 :1992
revision)

Polyethylene pipes for the supply of gaseous fuels ― Specification

14885:2001

Polyethylene/Aluminium/Polyethylene composite pressure pipes for

15450 : 2004
hot and cold water supplies ― Specification

IS 16462:2016 Plastic piping and ducting systems — Determination of the long-term

/ISO 9080:2012 hydrostatic strength of thermoplastics materials in pipe form by
extrapolation

3 TERMINOLOGY

For the purposes of this standard the following definitions shall apply:

3.1 Structural Definitions

3.1.1. Multilayer Pipe ‒ Pipe comprised of stress-designed inner polymeric layer and one
stress-designed metallic layer. The wall thickness of the pipe consists of at least 60 percent
of polymeric materials. For the purpose of this standard, the multilayer pipe is a three layer
(PE-AL-PE) pipe with stress-designed layer (inner layer) and outer layer of polyethylene
(PE), and the intermediate layer of aluminium.

3.1.2. Layer ‒ Homogeneous circumferential section of pipe wall that has chemical and/or
mechanical and/or physical characteristics different from those of its immediate neighbours.

3.1.3 Inner Layer ‒ Layer in contact with conveyed fluid.

3.1.4 Outer Layer ‒ Layer exposed to the external environment.

4
3.2 Geometric Definitions

3.2.1 Nominal Diameter (DN) ‒ Specified diameter assigned to nominal size (DN/OD or
DN/ID).

NOTE ― The nominal diameter is expressed in units of millimetres.

3.2.2 Outside Diameter, de ‒ Diameter measured through its cross-section at any point of a
pipe or the fitting end of a fitting, rounded to next greater 0.1mm.

3.2.3 Mean Outside Diameter ‒ Measured length of the outer circumference of the pipe
divided by π (≈ 3.142), rounded to the nearest 0.1 mm.

3.2.4 Inside Diameter ‒ Value of the measurement of the diameter, through its cross section
at any point of a pipe, rounded to next greater 0.1 mm.

3.2.5 Metal Layer Standard Dimension Ratio (SDRm) ‒ The nominal outside diameter (DN or
OD) divided by the nominal wall thickness of the metal layer.

3.2.6 Wall Thickness - Difference between the pipe outside diameter used for joining and
the pipe bore divided by 2.

3.2.7 Nominal Wall Thickness, en ‒ Wall thickness corresponding to the minimum wall
thickness at any point.
NOTE ― The nominal wall thickness is expressed in units of millimetres.

3.2.9 Mean Wall Thickness, em - Arithmetic mean of at least four measurements regularly
spaced around the same cross sectional plane of the pipe, including the measured minimum
and maximum value obtained, rounded up to the nearest 0.1 mm.

3.3 Definitions Related to Pressure

3.3.1 Design Pressure, PD - Highest pressure related to the circumstances for which the
system has been designed and intended to be used.

3.3.2 Predicted Design Pressure, PCD - Pressure that represents the predicted design
pressure after a lifetime of 50 years, using the 97.5 percent reference line.

NOTE ― The predicted design pressure is expressed in units of Kilopascals (bars).

3.4 Definitions Related to Material

3.4.1 Virgin Material - Material in a form such as granules or powder that has not been
subjected to use or processing other than that required for its manufacture and to which no
reprocessable or recyclable material has been added.

5
3.4.2 Rework Material - Material prepared from rejected unused pipes and fittings, including
trimmings from the production of pipes and fittings that can be reprocessed in a
manufacturer‘s plant after having been previously processed by the same manufacturer by a
process such as moulding or extrusion and for which the complete formulation is known.

3.4.3 Stress-Designed Layer - Plastics materials used for layers intended to be stress
bearing, and which shall be restricted to the reference material standards.

3.5 Definitions Related to Material Characteristics

-
3.5.1 Long Term Hydrostatic Strength (Long Term Pressure Strength) ─ Quantity with the
dimensions of stress, which represents the predicted mean strength at a temperature, T and
a time, t.
NOTE ― The long-term hydrostatic strength is expressed in units of mega pascals.

3.5.2 Lower Confidence Limit of the Predicted Hydrostatic Pressure PLPL - Lower confidence
limit of the predicted hydrostatic pressure, which represents the 97.5 percent (one-sided)
lower confidence limit of the predicted hydrostatic pressure at a temperature, T and a time, t.
NOTE ― The lower confidence limit of the predicted hydrostatic pressure is expressed in units of
kilopascals (bars).

3.5.3 Minimum Required Pressure (MRP) - Minimum required pressure, equal to the
estimated long-term pressure resistance of a pipe at temperature of 27 °C and a time of 50
years.

3.5.4 Design Coefficient Factor, C ─ Design coefficient with a value greater than 1, which
takes into consideration service conditions as well as properties of the components of a
piping system other than those represented in the lower confidence limit.
NOTE ― The minimum value of C for the purpose of this standard is 2.

3.6 Terms Related to Service Conditions

3.6.1 Gaseous Fuel ─ Any fuel which is in gaseous state at a temperature of 15 °C and a
pressure of 100 kPa (1 bar).

3.6.2 Category D Gaseous Fuel ─ Non-toxic Natural Gas

3.6.3 Category E Gaseous Fuel ─ Flammable and/or toxic fuels which are gaseous at
ambient temperature and atmospheric pressure conditions and are conveyed as gases
and/or liquids.

3.6.4 Maximum Operating Pressure, MOP ─ Maximum pressure at which a system can be
operated continuously under normal conditions.

6
4 REQUIREMENTS FOR THE SYSTEM

4.1 Pressure Drop

The manufacturer shall provide information on the pressure drop in the system.

4.2 Bending

Special attention shall be paid to the pressure drop of bends. Bending properties of the pipe
shall be stated by the manufacturer.

5 PIPES

5.1 Materials

5.1.1 Grades of Materials

The grade of PE material for the stress bearing layer (inner layer) and the outer layer shall be
as per Table 1.

Table1 Classification of PE Materials

(Clause 5.1.1)

Sl. Material Minimum Required Maximum Allowable

No. Strength (MRS) of Material Hydrostatic Design
at 20 °C for 50 years Stress, σ at 20 °C
MPa MPa
(1) (2) (3) (4)
i) PE 80 8.0 4.0

5.1.2 Characteristics of PE Compound

Materials intended for the stress bearing layer (inner layer) and the outer layer shall PE 80
grade conforming to the requirements in 5 of IS 14885. The characteristics of the PE
compound shall be as given in Table 2.
NOTES

1 Adhesives are not considered as stress bearing layers.

2 Only compounded material is permitted for the manufacture of these pipes. The compound supplier
shall provide the pipe manufacturer with certified test results for PE compound classification as per
Table 1 and its characteristics as per Table 2.

7
 Table 2 Characteristics of PE Compound
(Clause 5.1.2)

Sl. Characteristics Units Requirements Test Test Method

No. Parameter

(1) (2) (3) (4) (5) (6)

i) Base Density kg/m3 ≥ 930 23 C IS 7328

ii) Melt Flow Rate g/10 min ± 20 percent of 190 C/5 kg IS 2530
value nominated
by compound
producer
iii) Oxidation Induction min  20 200 C Annex A
Time
iv) Anti-oxidant By mass  0.3 percent - IS 2530

5.1.3 PE Compound Quality Evaluation

In order to establish the validity of classification for the material received by the manufacturer
and to get qualified for the production of PE-AL-PE multilayer pipes for supply of gaseous
fuel, an additional type approval test for long-term hydrostatic strength at 1 MPa, 20 °C for
10 000 h shall be conducted once on multilayer pipe with highest SDRm of the metal layer.

5.1.4 Rework Material

No rework material shall be used in the manufacture of the pipes.

5.1.5 Metallic Material

The metallic material, that is, aluminium used for manufacture of PE-AL-PE pipes shall be
Grade 31200 of IS 737 having minimum tensile strength of 95 MPa and minimum percentage
elongation of 20 percent.

5.2 GENERAL CHARACTERISTICS

5.2.1 Visual Appearance

The internal surface of the pipe shall generally be smooth, clean and free from grooving,
rings and poke marks which may effect the pipe performance. The ends shall be cleanly cut
and shall be square with the axis of the pipes. Slight shallow longitudinal grooves or
irregularities in the wall thickness shall be permissible provided that the wall thickness
remains within the permissible limits.

5.2.2 Colour
8
 Colour of the outer PE layer of the pipe shall be yellow.

5.2.3 Pigment Dispersion

The grading of pigment dispersion of outer PE layer when tested as per Annex B shall be
≤ 3.

5.2.4 Multilayer Pipe Construction

The joint line of metallic layer shall be continuously welded.

5.2.4 Minimum Design Coefficient

The minimum design coefficient, C shall be 2.

5.3 PRESSURE RATING

The PE-AL-PE composite pipe meeting the requirements of this specification shall be
pressure rated for maximum gas pressure of 500 kPa (5 bar).

5.5 DIMENSIONS OF PIPES

5.5.1 The dimensions of pipes shall be as per Table 3.

Table 3 Dimensions of Multilayer Pipe for Indoor Gas Installations

(Clause 5.5.1)

Sl Nominal Minimum Tolerance Maximum Total Wall Minimum Minimum Tolerance Minimum
No. Pipe Outside on Out of Thickness Wall Wall on Thickness
Size Diameter Minimum Round- Thickness Thickness Minimum of Outer
Outside ness of Inner of Aluminium Layer
Diameter layer Aluminium Thickness
Layer

Min Max
mm mm mm mm mm mm mm mm mm
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
i) 14 14.00 +0.30 0.3 1.70 2.10 0.70 0.18 +0.03 0.4
ii) 16 16.00 +0.30 0.4 1.70 2.10 0.90 0.18 +0.03 0.4
iii) 20 20.00 +0.30 0.6 1.90 2.30 1.00 0.23 +0.03 0.4
iv) 25 25.00 +0.30 0.6 2.30 2.80 1.10 0.23 +0.03 0.4
v) 32 32.00 +0.40 0.8 2.90 3.50 1.20 0.28 +0.03 0.4
vi) 40 40.00 +0.40 1.0 3.90 4.50 1.70 0.33 +0.03 0.4
vii) 50 50.00 +0.50 1.3 4.40 5.00 1.70 0.47 +0.04 0.4
viii) 63 63.00 +0.50 1.4 5.80 6.40 2.10 0.57 +0.04 0.4
ix) 75 75.00 +0.60 1.5 7.30 7.90 2.80 0.67 +0.05 0.4

9
5.5.2 Method of Measurements

5.5.2.1 The thickness of the outer layer of polyethylene, when tested as per Annex C, in the
PE-AL-PE pipe shall have a minimum value as specified in Table 3, except for polyethylene
material overlaying the weld, which shall have a minimum thickness of half that specified in
Table 3.

5.5.2.2 The outside diameter of pipe shall be taken as the average of two measurements
taken at right angles. The wall thickness shall be measured by a dial/digital vernier or ball
ended micrometer. The resulting dimension shall be expressed to the nearest 0.1 mm.

5.5.2.3 Ovality

Ovality (out of roundness) shall be measured as the difference between maximum outside
diameter and minimum outside diameter measured at the same cross section of the pipe. For
pipes to be coiled, the ovality shall be measured prior to coiling. For coiled pipes, however,
re-rounding of pipes shall be carried out prior to the measurement of ovality.

5.5.3 Length of Straight Pipe

The pipe shall be supplied in straight lengths of 3 m or 6 m, or lengths as agreed between

the manufacturer and the purchaser.

5.5.4 Coiling

While coiling, the inside diameter of coils shall not be less than 20 times the outside diameter
of pipe.

5.6 MECHANICAL PROPERTIES

5.6.1 Internal Pressure Creep Rupture Test

When subjected to internal pressure creep rupture test in accordance with procedure given in
Annex D, the pipes under test shall show no signs of localized swelling, leakage or weeping
and shall not burst during the prescribed test period. The temperatures, duration of test and
pressure for the test shall conform to those specified in Table 4.

Table 4 Internal Pressure Creep Rupture Test Parameters

(Clause 5.6.1)

10
 Sl Nominal Test Test Test
No. Pipe Pressure at Pressure at Pressure at
Size (27 ± 2) °C, (60 ± 2) °C, (95 ± 2) °C,
for 1 h for 10 h for 170 h
MPa MPa MPa

(1) (2) (3) (4) (5)

i) 14 3.0 2.5 1.3
ii) 16 3.0 2.5 1.2
iii) 20 2.8 2.5 1.0
iv) 25 2.8 2.5 1.0
v) 32 2.8 2.5 0.9
vi) 40 2.6 2.1 0.9
vii) 50 2.4 2.1 0.9
viii) 63 2.4 2.1 0.9
ix) 75 2.4 2.1 0.9

5.6.2 Strength of the Joint Line

The test shall be carried out in accordance with Annex E. When the outside diameter of the
pipe is increased by 10 percent, no failures relative to the joint line of the metal layer shall
occur.

5.6.3 Resistance to Slow Crack Growth of the Outer Layer (Cone Test)

The test shall be carried out on pipe produced from material used for the outer layer in
accordance with Annex F. The crack growth rate shall be less than 10 mm/day.

5.7 PHYSICAL PROPERTIES

Pipes shall fulfill requirements for physical properties as given in Table 5.

Table 5
Physical Properties
(Clause 5.7)
Sl Characteristics Requirements Tests
No. Parameters Values Reference
i) Resistance to ≥ 20 h Conditioning 1 500 h/ Annex G
gas constituents No delamination (23±2) °C
Temperature 80 °C
Cone Test 10 percent
expansion

No delamination Conditioning 1 500 h/

(23±2) °C
Temperature (23±2) ⁰C
Pressure 0.4 PD

11
Sl Characteristics Requirements Tests
No. Parameters Values Reference

ii) Thermal No visual cracks in At 100 °C or 0.5 year Annex H

Durability of outer layer (PE) At 110 °C 0.25 year
Outer layer Strain 3 percent
iii) Delamination Peel strength ≥ 15 Temperature (23±2) °C Annex J
N/cm Cycling Test (-20±2) °C/
(+60±2) °C
No. of Cycles 10
iv) Odorant No perception of Odorant THT Annex K
Permeability Tetrahydrothiophene Exposure 60 days
(THT) or any other time
odorant (as permitted Temperature (23±2) °C
by the concerned
statutory authority)
smell by experienced
observer

6 FITTINGS

6.1 General

6.1.1 Mechanical fittings shall be used. The pipes and fittings of the same make shall
preferably be used. However, in case fitting of different make is to be used, then the fitting
manufacturer shall establish compatibility of those fittings with pipes as an integrated system
meeting the requirements of this standard, through tests as given in this standard.

6.1.2 Installation

During installation of the fitting on the pipe, the aluminium layer, and in particular the welded
seam, shall not be torn.

Tools and aids used for installation of the fitting shall not damage the pipe and/or fitting.

6.2 Materials

The materials used in stress-designed fitting components shall be such that the level of
performance of these components shall be at least equal to the performance of the multilayer
pipe specified in relation to the application. The fitting shall be manufactured from De-
Zincification (DZR) brass or brass conforming to IS 319, and shall not be casted.

6.3 Dimensions of Fittings

12
The mechanical fittings shall be manufactured with such dimensions and within such
tolerances that the fittings for the corresponding pipe sizes shall meet the requirements of
7.2.

6.4 Transition Fittings

The manufacturer shall provide a transition fitting intended to be connected to a standardized

system. The connection shall comply with the relevant standards, for example, IS 554.

6.5 Rubber Rings

Rubber rings used for the fittings shall be of nitrile rubber with Shore –A hardness 60-70.

7 FITNESS FOR PURPOSE

7.1 Diameter Classes

The diameter classes which are defined based on ranges of the external diameter shall be as
per Table 6.

Table 6 Diameter Classes

(Clause 7.1)
Sl Character- Diameter Class
No. istics
1 2 3 4 5 6 7
(1) (2) (3) (4) (5) (6) (7) (8) (9)
i) External de < 16 16 ≤ de < 20 20 ≤ de < 26 26 ≤ de < 40 40 ≤ de < 50 50 ≤ de < 60 60 ≤ de ≤ 75
diameter, in
mm
ii) Nominal 14 16 20 and 25 32 40 50 63 and 75
pipe size, in
mm

7.2 Requirements

To avoid gas diffusion between the layers, the pipe shall be sealed in the joint at the inner-
layer. Joint assemblies shall fulfill the requirements of Table 7 for the complete diameter
range of the multilayer system.

Table 7 REQUIREMENT FOR FITNESS PURPOSE OF JOINT ASSEMBLIES

(Clause 7.2)
Sl Characteristic Requirements Tests
No.

Parameter Value Reference

(1) (2) (3) (4) (5) (6)
i) Long term No Leakage Test Temperature (60 ± 2) °C Annex D

13
Sl Characteristic Requirements Tests
No.

Parameter Value Reference

(1) (2) (3) (4) (5) (6)
internal Type of test End fitting – pipe –
pressure test for sample coupler – pipe – end
joint assembly fitting
Test Pressure 600 kPa (6 bars)
Test Duration 1 000 h
ii) Tensile Load No leakage for Test temperature (23±2) °C Annex L
one hour Type of test End fitting – pipe – end
samples fitting
Pipe length 350 mm
No. of test 2 per diameter class
samples
Test Pressure 3 kPa (0.03 bar)
Tensile Strength Class Strength (KN)
Level 1h 800 h
test test
1 1.4 0.7
2 1.8 1.0
3 2.1 1.4
4 4.0 2.4
5 6.0 3.6
6 8.0 4.8
7 12.0 7.2
iii) Joint resistance to Tightness Test temperature (23±2) °C Annex M
Crushing No reduction of Type of test End fitting – pipe – end
outer diameter sample fitting
more than Pipe length 600 mm
20percent
Number of test 2 per diameter class
samples
Test pressure 3 kPa (0.03 bar)
Force Level 2 kN
Position of load 10 mm from the insert of
applied fitting or nut
Load Plate with 150 mm side
square
iv) Impact Resistance Tightness Test Parameter (23±2) °C Annex N
of the Joint Type of test End fitting – pipe –
sample coupler – pipe – end
fitting with each end
fitting fixed on a
motionless support
Pipe length 1 000 mm each pipe
No of test sample 2 per diameter class
Test pressure 3 kPa (0.03 bar)
Striker Spherical head with

14
 Sl Characteristic Requirements Tests
No.

Parameter Value Reference

(1) (2) (3) (4) (5) (6)
1 cm of radius
Impact 600 mm height, 5 kg
weight of striker
Position of the On to the fitting
impact
v) Thermal cycling No leakage Extreme test (-20±2) °C / (60±2) °C Annex P
resistance temperature
Number of cycles 10
Type of test End fitting – pipe –
samples coupler – pipe – end
fitting assembled at
(0±2)°C
Pipe length 300 mm each pipe
Number of test 2 per diameter class
samples
Test pressures 10 kPa (0.10 bar); and
1.5 times MOP
[Minimum of 600 kPa (6
bar)]
vi) Repeated bending No damage or Minimum bend As declared by the Annex Q
Resistance modification of radius manufacturer
the aluminium Bend angle 90°
layer after the test Number of 3
bending cycles
Test pressure 3 kPa (0.03 bar)
Type of test End fitting – pipe – end
samples fitting
Pipe length 350mm
Position of the At a distance equal to
bend one minimum bend
radius from the end
fitting
Number of test 4 per diameter class
samples
vii) Leak tightness No leakage Test temperature (27±2) ⁰C Annex D
Type of test End fitting –pipe-
sample coupler- end fitting

Pipe length 300 mm

Test pressure 750 kPa (7.5 bars)
Test duration 5 min

8 SAMPLING, FREQUENCY OF TESTS AND CRITERIA FOR CONFORMITY

8.1 Type Test

15
8.1.1 Type tests are intended to prove the suitability and performance of a new composition,
a new manufacturing technique or a new size of pipe. Such test need to be applied only
when a change is made in polymer composition or method of manufacture, or when a new
size is to be introduced. Even if no change is envisaged, type test shall be done at least
once in three years of the highest size manufactured during the period.

8.1.2 Three samples selected at random shall be tested for compliance with the requirements
of the type tests as given in Table 8.

8.1.3 If all the samples pass the requirements of the type test, the type of the pipe under
consideration shall be considered eligible for type approval.

8.1.4 In case, any of the samples fail in the type test, the testing authority, at its discretion,
may call for fresh samples not exceeding the original number and subject them to the type
test again. If in repeat test, no single failure occurs, the type of pipe under consideration shall
be considered eligible for type approval. If any of the samples fail in the repeat tests, the type
of pipe shall not be approved. The manufacturer or the supplier may be asked to improve the
design and resubmit the product for type approval.

8.1.5 At the end of the validity period (normally three years) or earlier as may be necessary,
the testing authority may call for fresh samples for type-test for the purpose of type approval.

8.2 Acceptance Test

8.2.1 Acceptance tests are carried out on sample selected from a lot for the purpose of
acceptance of the lot. The scale of sampling and criteria for conformity of a lot for acceptance
tests specified in Table 8 shall be as given in 8.2.2.

Table 8 Type and Acceptance Tests

(Clauses 8.1 and 8.2)
Sl Description of Test Clause/ Table No. Acceptance Type Test
No. Test
(1) (2) (3) (4) (5)
1 Base density 5.1.2; Table 2 
2 Melt flow rate 5.1.2; Table 2 
3 Oxidation induction time 5.1.2; Table 2 
4 Visual appearance 5.2.1 
5 Colour 5.2.2 
6 Pigment dispersion 5.2.3 
7 Pipe dimensions 5.5 

16
 Sl Description of Test Clause/ Table No. Acceptance Type Test
No. Test
(1) (2) (3) (4) (5)
8 Internal pressure creep 5.6.1 
rupture test (1 h and 10 h
test)
9 Internal pressure creep 5.6.1 
rupture test (170 h test)
10 Strength of joint line 5.6.2 
11 Resistance to slow crack 5.6.3 
growth of the outer layer
(cone test)
12 Resistance to gas 5.7 ; Table 5 
constituents
13 Thermal durability of the 5.7 ; Table 5 
outer layer
14 Delamination 5.7 ; Table 5 
15 Odorant permeability 5.7 ; Table 5 
16 Long term internal pressure 7.2 ; Table 7 
test of joint assembly
17 Tensile load 7.2 ; Table 7 
18 Joint resistance to crushing 7.2 ; Table 7 
19 Impact resistance of the 7.2 ; Table 7 
joints
20 Thermal cycling resistance 7.2 ; Table 7 
21 Repeat bending resistance 7.2 ; Table 7 

8.2.2 Scale of Sampling and Criteria for Conformity for Acceptance Test

8.2.2.1 Lot

All pipes/coils of the same size and manufactured essentially under similar conditions of
manufacture with same grade of material shall constitute a lot.

8.2.2.2 For ascertaining the conformity of the lot to the requirement of this specification,
samples shall be selected and acceptance tests as in Table 8 conducted in accordance with
the provisions as given in 8.2.3 and 8.2.4 and tested for compliance.

8.2.3 Visual, Color and Dimensional Requirements

8.2.3.1 The number of test samples shall be in accordance with Table 9.

17
8.2.3.2 The pipes/coils shall be selected at random from the lot and in order to ensure the
randomness of selection a random number table shall be used. For guidance and use of
random number table, IS 4905 may be referred. In absence of a random number table the
following procedure may be adopted:

Starting from any pipe in the lot, count them as 1,2,3,4 etc, up to r and so on where r
is the integral part of N/n, N being the number of pipes in the lot and n is the number
of pipes in the samples. Every rth pipe so counted shall be drawn so as to constitute
the required sample size.

8.2.3.3 The number of pipes given for the first sample in col 4 of Table 9 shall be examined
for visual and dimensional requirements given in 5.2.1, 5.2.2 and 5.5. A pipe failing to satisfy
any of these requirements shall be considered as defective. The lot shall be deemed to have
satisfied these requirements, if the number of defectives found in the first sample are less
than or equal to the corresponding acceptance number given in col 6 of Table 9. The lot shall
be deemed not to have met these requirements, if the number of defectives found in the first
sample is greater than or equal to the corresponding rejection number given in col 7 of Table
9. If however, the number of defectives found in the first sample lies between the
corresponding acceptance and rejection numbers given in col 6 and col 7 of Table 9, second
sample of size given in col 4 of Table 9 shall be taken and examined for these requirements.
The lot shall be considered to have satisfied these requirements if the number of defectives
found in the cumulative samples is less than or equal to the corresponding acceptance
number given in col 6 of Table 9; otherwise not.

Table 9 Scale of Sampling for Visual and Dimensional Requirements

(Clause 8.2.3.1)
Sl No. of Sample Sample Cumulative Acceptance Rejection
No. Pipes/Coils in No. Size Sample No. No.
the lot Size
(1) (2) (3) (4) (5) (6) (7)
First 3 3 0 2
i) Up to 25
Second 3 6 1 2
First 13 13 0 2
ii) 26 to 150
Second 13 26 1 2
First 20 20 0 3
iii) 151 to 280
Second 20 40 3 4
First 32 32 1 4
iv) 281 to 500
Second 32 64 4 5
First 50 50 2 5
v) 501 to 1 200
Second 50 100 6 7

8.2.4 The lot having satisfied dimensional and visual requirements shall be tested for internal
pressure creep rupture test (1 h and 10 h), density, MFR, pigment dispersion, OIT, strength
of joint line of pipe test requirements and joint resistance to crushing, impact resistance of
joints and repeat bending test for pipe fitting joint test requirements.
18
8.2.4.1 A separate sample size for each of the tests shall be taken as stipulated in Table 10
and selected at random from the sample already examined for dimensional visual inspection
and colour. All the pipes in each of the sample size shall be tested for compliance in the
requirement for internal pressure creep rupture test for 1 h and for 10 h (see 5.6.1), density
(see Table 1), MFR (see Table 1), pigment dispersion (see 5.2.3), OIT (see Table 1),
strength of joint line (see 5.6.2), joint resistance to crushing (see Table7), impact resistance
of joints (see Table 7) and repeat bending resistance test (see Table 7) . The lot shall be
considered to have met the requirements of these tests, if none of the sample tested fails.

Table 10 Scale of Sampling

(Clause 8.2.4.1)

Sl No. of Pipes/Coils in the Sample Size

No. Lot

(1) (2) (3)

i) Up to 100 3
ii) 101 to 150 4
iii) 151 to 200 5
iv) 201 and above 8

9 MARKING AND DOCUMENTATION

9.1 Marking on Pipe

Each straight length or coil of pipe shall be clearly and legibly marked with any one of the
following methods, such that the marking shall not initiate cracks or other types of failure in
the product and the colour of the marking shall differ from that of the external pipe surface:
a) Indelible inkjet print at every meter interval throughout the length of pipe/coil, or
b) Laser print on at every meter interval throughout the length of pipe/coil.

Following minimum information shall be marked, and same shall be maintained during storage,
handling, installation and use:

Sl Aspect Mark or Symbol

No.

i) Name of the manufacturer or trade mark Name or Symbol

ii) Internal Fluid Gas
iii) Maximum operating pressure 500 kPa (5 bar)

19
 iv) Nominal pipe size XX

v) Material Designation PE- AL-PE

vi) Type and grade of PE material PE80

vii) Lot no. / Batch no. As per 9.1.1

viii) Reference to this Indian Standard IS_________

9.1.1 The lot number/batch number shall include the details of production in the following
manner:

Year Month Day Machine No. Shift

xxxx xx xx xxx x

9.2 Marking on Label

Two labels of suitable dimensions should be carefully attached to each coil/pipe bundles
indicating:

a) Manufacturer’s name;
b) Manufacturing standard;
c) Material designation;
d) Weight of coil/pipe bundle in kg; and
e) Length of coil/each pipe length, in m.

9.3 Additional Instructions

The manufacturer shall provide clear assembly instructions that contains at least the
following information:

a) instructions that pipe and fitting(s) belong together and are not interchangeable with
other products;
b) statement if a fitting is fit for repeated assembly;
c) if the manufacturer allows the use of a standard bending tool, a statement in the
manufacturer’s instructions that damage of the external coating shall be avoided while
bending the pipe with standard bending tool;
d) information on gaseous flow rate/pressure drop relationship;
e) minimum bending radius;
f) bending tools to be used; and
g) if a calibration tool is necessary to insert a stiffener, the manufacturer instructions shall
be given.

9.4 BIS Certification Marking

20
The pipes conforming to the requirements of this standard may be certified as per the
conformity assessment schemes under the provisions of the Bureau of Indian Standards Act,
2016 and the Rules and Regulations framed thereunder, and the reinforcement coupler may
be marked with the Standard Mark.'

21
 ANNEX A
(Table 2)

METHOD FOR DETERMINATION OF OXIDATION INDUCTION TIME

A-1 APPARATUS

A-1.1 A differential thermal analyser (DTA), calibrated using pure indium and pure tin to give
values which lies within 156.6 ± 0.5 °C and 231.9 ± 0.5 °C respectively.

The test cell shall allow the cell to be purged within 1 min by use of successive gases at the
specified flow rate.

A-1.2 Aluminium pans, large enough to accommodate a test piece in solid or molten form.

A-2 TEST PIECES

A sample shall be taken by use of a core drill directed radically through the pipe wall. The
diameters of the core shall be just less than inner diameter of the sample pan of the thermal
analyzer and care should be taken not to overheat the sample during the coring operation.
Using a scalpel, test pieces that weigh 15 ± 0.5 mg shall be cut in the form of discs from the
core sample, electing the inner surface and outer surface as the minimum sample points,
which are then to be tested individually.

A-3 PROCEDURE

Except where the method given below differs, follow the operating instructions of the
instrument manufacturer as applicable:

a) Establish a nitrogen flow of 50 ml/min through the DTA cell. Check that when a
switchover to nitrogen is made, the gas flow will continue at the rate and then revert to
a nitrogen flow of 50 ml/min.
b) Introduce a test piece in an open aluminium pan and an empty aluminium reference
pan into the cell. Set the instrument to raise the temperature at a rate of 20 °C/min
and then to run isothermally at 200 ±0.1 °C. Start to record the thermogram (that is, a
plot of the temperature differential against time).
c) When steady condition exists under nitrogen after 5 min, switch over to oxygen and
mark this point on the thermogram.
d) Continue to run the thermogram until the oxidation exotherm has occurred and has
reached its maximum.

A-4 INTERPRETATION OF THE RESULTS

The oxidation induction time for the test is the time taken, in min from the introduction of
oxygen to the intercept of the extended base line and the extended tangent drawn to the
exotherm at the point of maximum slope, as shown in Fig. 1.

22
 Fig. 1 Temperature Differential (∆T) against Time

A-5 TEST REPORT

The test report shall include the following:

a) identification of the test piece;

b) a reference to this test method;
c) individual results, in min; and
d) date of the test.

23
 ANNEX B
(Clause 5.2.3)

ASSESSMENT OF PIGMENT DISPERSION IN

POLYETHEYLENE PIPES: MICROTOME METHOD

B-1 SCOPE

This annex describes the method for the assessment of pigment dispersion in polyethylene
pipes.

B-2 PRINCIPLE

A microtome section of material is examined by transmitted light at a magnification of X100

and compared against standard photomicrographs.

B-3 APPARATUS

Apparatus required for the test are,

a) Microtome ― A microscope of at least X100 linear magnification and circular field of

view of 0.7 ± 0.07 mm diameter set for transmitted light.

b) Microscope slides and cover slips

B-4 TEST PIECE

Microtome section of 10 micron to 20 micron thick shall be cut from outer layer of the pipe. It
shall have an area of approximately 7.0 mm2. Six test pieces shall be taken from different
parts of the pipe length.
NOTE ― It is often easier to take microtome sections if the pipe has been cooled to below room
temperature.

B-5 PROCEDURE

a) Place the pieces on a microscope slide so that each one is equidistant from its
neighbour(s) and from adjacent edge(s) of the slide and cover with Canada balsam
before placing a cover slip over the test pieces.

b) Examine the six test pieces in turn through the microscope at a linear magnification of
X100 ± 10.

c) Scan the whole of each test piece and compare the worst field of view of each with
the standard photo-micrographs numbered 1 to 6 as shown in Fig. 2.
d) Give to each of the six test pieces a numerical rating corresponding to the number of
the photomicrograph equivalent to the worst field of view of each test piece.

24
B-6 EXPRESSION OF RESULTS

Record the rating of each test piece as per Fig. 2.

Fig. 2 Pigment Dispersion Photomicrograph 1 to 6

25
B-7 TEST REPORT

The test report shall include the following:

a) Full identification of pipe or fitting from which the test pieces were taken,
b) Individual rating of each test piece, and
c) Date of testing.

26
 ANNEX C
(Clause 5.5.2.1)

OUTER POLYETHYLENE LAYER THICKNESS

C-1 SAMPLE PREPARATION

Select the sample of pipe at random. Cut the pipe with a sharp knife or other suitable cutter,
ensuring that the pipe after cutting is not more than 1 percent out-of-roundness.

C-2 THICKNESS DETERMINATION

Use a hand held magnifying glass equipped with graduated reticule or a laboratory
microscope with graduated reticule. The reticule should measure to the nearest 0.10 mm.
Determine the thickness of outer coating of polyethylene at six points around the
circumference. Only one of the points should be at the aluminium weld.

27
 ANNEX D
(Clause 5.6.1 and Table 7)

INTERNAL PRESSURE CREEP RUPTURE TEST

D-1 SAMPLES

Each test sample of PE-AL-PE pipe shall have a minimum length between end closures of at
least ten times the average outside diameter of the pipe, but not less than 250 mm. Seal
specimens at both ends with appropriate fittings and fill the sample with water.

D-2 TEST PROCEDURES

Test each sample individually in a temperature controlled water bath. Condition the test
samples for at least 2 h in the water bath when the water bath is at the required test
temperature. Maintain the pressure indicated in Table 4 within 0.07 MPa of the set pressures
for the duration of the test.

D-3 FAILURE

Any continuous loss of pressure of the test sample shall constitute failure of the test.

28
 ANNEX E
(Clause 5.6.2)

TEST FOR DELAMINATION AND STRENGTH OF THE JOINT LINE

E-1 PRINCIPLE

Pipe samples are subjected to a cone test in order to determine delamination and strength of
the joint line of the pipe sample. With a specially shaped cone, a defined expansion of the
pipe is created.

E-2 PIPE SAMPLE

The test shall be carried out on a pipe sample with a length of at least 5 times de.

E-3 CONE

A cone with an angle of 15° shall be applied. The length of the cone shall be such that an
expansion of the pipe end of 10 percent can be obtained.

E-4 PROCEDURE

The test shall be carried as per the procedure given below:

a) Measure the real mean outside diameter of the pipe sample using suitable equipment
with an accuracy of at least 0.1 percent.

b) Multiply this value by 1.1 (10 percent expansion). This value is the outside diameter of
the expanded part of the pipe sample.

c) Measure the wall thickness of the pipe sample at eight separate points equally divided
over the pipe diameter with an apparatus having an accuracy of at least 1 percent.
The calculated value is em.

d) Calculate dcone, the required size of the cone diameter in order to obtain an expansion
of 10 percent, using the formula, dcone = [1.1de − (2em)].

e) Mark the place on the cones where a 10 percent expansion is expected.

f) Insert the cone in the pipe sample up to the mark sign. The pipe end has been
expanded now by 10 percent.

g) Remove the cone.

h) Wait 15 min after the removal of the cone and visually check the sample for cracks
and delamination.

29
E-5 TEST REPORT

The test report shall include the following:

a) number, type and nominal dimension of the sample;

b) test temperature;
c) cone dimensions;
d) duration of the test;
e) any observation made during and after the test; and
f) any event able to influence the test results.

30
 ANNEX F
(Clause 5.6.3)

RESISTANCE TO SLOW CRACK GROWTH OF THE OUTER LAYER (CONE TEST)

F-1 PRINCIPLE

The test is conducted on a pipe produced from the material used for the outer layer of
multilayer pipe. Rings cut from pipe to a specified length are held at a constant strain by
insertion of a mandrel and a single notch is made at one end of the pipe ring. The assembly
is immersed in a specified surface-active solution held at a temperature 80 ⁰C ± 1 ⁰C. The
rate of growth of crack propagating from the notch is measured. The test is applicable to pipe
of wall thickness up to and including 5 mm.

F-2 MATERIAL

Surface active solution of 5 percent Nonyl-phenoxy (ethyleneoxy) ethanol neutral type

detergent mixed in de-ionized water (concentration by weight) shall be used.

F-3 APPARATUS

F-3.1 Thermostatically Controlled Tank

Thermostatically controlled tank to contain the surface active solution having dimensions to
ensure full immersion of the specimen to be tested, shall have a lid to cover to prevent
evaporation and a means of stirring the solution.

F-3.2 Cone

A mandrel of dimension as specified in Fig. 3 and with a conical end is required for insertion
into the pipe ring to maintain a constant strain. At the end of the mandrel, there shall be a
longitudinal groove of dimensions 20 ± 1 mm by 1 ± 0.2 mm and depth 2 ± 0.2 mm. The
material used for manufacture of the mandrel shall not affect the surface active solution,
brass for example.

31
Key:

D = 1.12 times the nominal internal diameter of the pipe (±0.1 mm);

H = D, for nominal outer diameter not exceeding 40 mm, and

= D/2, for nominal diameters above 40 mm; and

R = 4 times the specified internal diameter of the pipe, for the pipe nominal size less
than or equal to 40 mm, and
= nominal internal diameter of pipe for nominal size above 40 mm.

The nominal internal diameter is equal to the nominal pipe size less twice the specified
minimum wall thickness

Fig. 3 Cone

F-3.3 Press or Vice

A press to drive the mandrel into the pipe ring at a rate which will not cause damage or
distort the end or edges of the ring. Alternatively a vice with retaining and guiding jaws can
be used.

F-3.4 Notching Device

A notching device is required which is capable of inserting a razor blade into the end of the
pipe to create a notch, as shown in Fig. 4. Alternatively a mechanised means of performing
32
this operation, such as using a specialised jig or a machine with a moving table, is
acceptable.
NOTE ― A commercial razor blade shall be used for this operation, which shall be changed after not
more than 20 notching operations. A blade penetration speed of around 10 mm/min is recommended.

F-4 Test Piece

Prepare three ring test pieces of 100+5 mm length from a sample of pipe. Ensure that the
ends of the ring are cut square. Measure the outer diameter (D1) of the specimen 30 mm
form the end of the pipe ring.

Fig. 4 Notching Device

F- 5 PROCEDURE

F- 5.1 Insertion of the Cone

Carefully insert the cone into the pipe ring ensuring axes of both are aligned. Using the press
or vice, drive the mandrel fully into the pipe ring at a rate which shall not damage or distort

33
the end or edges of the ring. Re-measure the diameter (D2) of the pipe in the same position
30 mm from the end.

Following insertion of the cone, the test piece shall be notched and immersed in the surface
active solution within 10 min.

F-5.2 Calculation of Strain

Calculate the strain, using following formula and expressing the result as a percentage:

Strain = [(D2 – D1) x 100]/D1

F-5.3 Cutting of the Notch

A radial notch of axial length 10±1 mm shall be cut through the pipe wall at the end of the
pipe ring, which has been fully strained by the mandrel. The circumferential position of the
mandrel groove relative to the pipe shall be marked. The notch shall be cut using the
notching device.

To ensure that the notch is extended through the full wall thickness of the pipe ring specimen
a press or vice shall be used to push the notching device into the ring.

Measure the axial length of the notch from the end of the pipe, A0 ± 0.5 mm.

NOTE ― Mechanized means of cutting the notch is acceptable. For instance, the test assembly may be
held in a tensile test machine or a special jig allowing the blade to form the notch in a controlled way. A cutting
speed of around 10 mm/min is recommended.

F-5.4 Immersion of Test Piece

Introduce the test piece with inserted mandrel, after notching, into the tank containing the
surface active solution, maintained at a constant temperature of 80 ±1 ⁰C. The test piece
shall be positioned vertically in the tank, fully immersed, with the end of the mandrel sitting on
the bottom of the tank, that is, with conical end facing upwards. The lid shall be placed on
the tank and sealed.

F-5.5 Measurement of Crack Growth

The axial notch shall be examined after every 24 h. The appearance shall be noted and the
length of the notch from the end of the pipe (A1) shall be measured at each 24 h with
precision of ±0.5 mm. At least three successive increases in the notch length shall be
obtained. If the notch growth curves away from an axial path significantly, the test shall be
stopped and a new sample should be prepared.
NOTE ― If no crack growth occurs after one week in the three test pieces, the test shall be stopped.
The specimen of the pipe is deemed to be resistance to slow crack growth.

F-6 EXPRESSION OF RESULTS

34
Plot a graph of increase in crack length (A1 – A0) verses time, as shown in example in Fig. 5.
Carry out linear regression for the data set. Determine the rate of growth (V mm/24 h) from
the slope of this line for each test specimen. The highest rate of growth of crack shall be
reported.

Fig. 5 Increase in crack length vs time

35
 ANNEX G
(Table 5)

RESISTANCE TO GAS CONSTITUENTS

G-1 PRINCIPLE

Specimens of pipe/fitting assemblies are filled with a liquid containing 50 percent n-decane
and 50 percent 1,3,5- tri-methyl benzene under pressure for a specified period. After this
conditioning period a cone test is carried out on the pipe as per G-3.1 in order to determine
the grade of delamination and an internal pressure test is carried out at 80 °C for a duration
of 20 h as per G-3.2 in order to determine the grade of delamination.

G-2 SPECIMEN

Prepare four specimens in accordance with IS 12235 (Part 8/Section 1). The test specimen
should preferably be made of a pipe from dimension Class 6 (see 7.1). The end caps shall be
mounted in such a way that the condensate has free access to the pipe ends.

G-3 PROCEDURE

G-3.1 Cone test

The cone test shall be conducted as per the procedure given below:

a) Prepare a synthetic condensate consisting of a mixture of a mass fraction of 50

percent n-decane (99 percent) and a mass fraction of 50 percent 1,3,5-
trimethylbenzene.
b) Condition the pipe by filling it with condensate and allowing it to stand in air for 1 500 h
at 23 ± 2 °C with a pressure of 0.4 PD.
c) Thereafter, the pipe shall be tested in accordance with Annex C, taking into account
the dimensions of the pipe after conditioning.
d) Check the specimen for leakage and for delamination of the layers.

G-3.2 Internal Pressure Test

The internal pressure test shall be conducted as per the procedure given below:

a) Prepare a synthetic condensate consisting of a mixture of a mass fraction of 50

percent n-decane (99 percent) and a mass fraction of 50 percent 1,3,5-
trimethylbenzene.
b) Condition the pipe by filling it with condensate and allowing it to stand in air for 1 500 h
at 23 ± 2 °C with a pressure of 0.4 PD.
c) After the above procedure, an internal pressure test shall be carried out at 80 ± 2 °C
for a duration of 20 h.
d) Check the specimen for leakage and for delamination of the layers.

36
G-4 TEST REPORT

The test report shall include the following:

a) number, type and nominal dimension of the specimen;

b) test temperature;
c) duration of the test;
d) any observation made during and after the test; and
e) any event able to influence the test results.

37
 ANNEX H
(Table 5)

THERMAL DURABILITY OF OUTER LAYER

H-1 PRINCIPLE

A pipe sample is stored in an oven for a defined time at an elevated temperature. After this
oven aging, the test piece is bent to produce a required axial strain in the outside layer. The
layer is observed visually for cracks.

H-2 APPARATUS

H-2.1 Hot air oven capable of maintaining 100 ± 2° C or 110 ± 2 °C.

H-2.2 Bending template, as shown in Fig. 6.

Fig. 6 Diagram of Typical Bending Apparatus

H-3 PROCEDURE

The test shall be carried out as per the procedure given below:
38
H-3.1 Age the Polyethylene (PE) in an oven for 0.5 years at (100 ± 2) °C or 0.25 years at
(110 ± 2) °C.

NOTE ― This assumes a duration of 25 years at 60 °C during the 50 year lifetime of the pipe. Taken into
account is the time/temperature extrapolation method of IS 16462/ISO 9080, which gives a test time of 0.5
years (6 months) at 100 °C or 0.25 years (3 months) at 110 °C.

These oven aging times and temperatures are based on temperature profiles. The
temperature variation is assumed as follows:

120 h at 70 °C per year, 3 months at 60 °C, 3 months at 50 °C, 3 months at 40 °C and

3 months at 30 °C.

H-3.2 Deform the test piece by bending with bending template at 23 ± 2 °C for a duration
ranging from a minimum of 3 s to a maximum of 10 s (for complete deformation) and using
the parameters as given below:

Total Pipe Length Bending Length Bending Radius

l1 l2 R

10 de 7.5 de 16 de

Where, de is the outside diameter of the pipe.

A strain of 3 percent is required, equivalent to a bending radius of 16 de.

An example for calculating the relationship between bending radius and strain is given below:

EXAMPLE ― For a pipe with 32 mm outside diameter, the required bending template radius
is calculated as follows:

R = 16 × de = 16 × 32 mm = 512 mm

Strain of the outer layer in relation to the neutral axis of the pipe is calculated as follows:
ε = [{(R + de)/(R + 0.5de)} – 1] = [{(17 × de)/(16.5 × de)} – 1] = 0.0303 = 3.0 percent

H-4 TEST REPORT

The test report shall include the following:

a) number, type and nominal dimension of the sample;

b) presence of cracks;
c) duration of the test;
d) any observation made during and after the test; and
e) any event able to influence the test results.

39
 ANNEX J
(Table 5)

ADHESION TEST (DELAMINATION TEST)

J-1 PRINCIPLE

Adhesion strength between layers of multilayer pipes is determined by a peel test using a
pulling test rig. A tensile force is introduced to the metal (embedded) layer of a test piece
perpendicular to the axial direction. This pulling force is measured. The test is carried out
before and after thermal cycling.

J-2 PEEL TEST

J-2.1 Apparatus

J-2.1.1 Tensile Testing Machine

Tensile testing machine with cross head speed of 50 mm ± 5 mm per min having measuring
accuracy of 1 N is recommended.

J-2.1.2 Rotating Test Rig

For every pipe diameter (di), a support mandrel, having an outside diameter of 0.95 di and a
length of at least 12±1 mm, able to rotate without significant resistance, preferably by the
inclusion of a roller bearing, and a pulling rig, conforming to the principle as given in Fig. 7.

J-2.2 Sampling and Preparation of Test piece

Total 10 samples shall be cut from the pipe to be tested, equally divided over 1 m of the pipe.
Each test piece shall be ring of width 10 mm cut from the pipe. The metal layer shall be cut in
the axial direction and pulled lose over fixed length less than 12 mm to enable the clamp to
be attached for pulling. For the location of the joint line, to neutralize the negative influence
of the cutting, two series of tests shall be performed at different angles, α, as given below:

a) For Test 1, the angle, α shall be 135° ±5°, see Fig. 7; and
b) For Test 2, the angle α shall be 315° ±5°.

This test shall be carried out keeping the joint in the center of the test rings in both the tests.

J-2.3 Procedure

a) The test shall be conducted at 23±2 °C.

b) Insert the support axle into the test piece and ensure free rotation of test piece.
c) Install the clamp on the lose part and check that the angle α is as required for Test 1
and Test 2.
d) Apply a cross-head spread speed of 50±5 mm/min.
40
 e) Record the applied force, Fp, over the angle of rotation 30° to 255° during the test.

Key

1 Clamp
2 Inner layer
3 Support axle that includes a roller bearing
4 Weld line
5 Pivoted sample holder

Fig. 7 Pulling Rig

J-2.4 Processing of Test Result

For all 10 samples, the minimum value of Fp is recorded as the peel strength.

J-3 DELAMINATION TEST

J-3.1 Sample

Samples for peel test and for thermal cycling shall be prepared in accordance with J-2.2 and
Annex P, respectively. All samples shall be prepared from the same pipe.

J-3.2 Procedure

The test shall be conducted as per the procedure given below:

a) Carry out a peel test according to J-2 at 23 ± 2 °C.

b) Carry out a thermal cycle test according to Annex P, with a thermal cycle between
−20 °C and 60 °C. The number of cycles shall be 10. The pipe is to be pressurized.

41
 c) After the thermal cycling, a test sample shall be prepared for the peel test according to
J-2.2 and peel test shall be carried out according J-2 at 23 ± 2 °C. The peeling zones
should be at the ends and center of the test piece.

J-4 TEST REPORT

The test report shall include the following:

a) peel strength, expressed in N/cm;

b) name of the test;
c) number, type and nominal dimension of the sample; and
d) test temperature.

42
 ANNEX K
(Table 5)

ODORANT PERMEABILITY TEST

K-1 PRINCIPLE

A flow with a defined concentration of THT (see Note) is conveyed through a pipe sample.
After a defined period, the THT permeability through the pipe wall will be detected by an
experienced person.
NOTE ― THT (Tetrahydrothiophene) is the most common type of odorant that is added to the gas for
safety reasons. A customer can detect small gas leakages by smelling. Any other odorant permitted by statutory
authorities may also be used for this test.

K-2 SAMPLES

Each end of a pipe is fitted with a valve. The length of the pipe is such that the distance
between the valves shall be 250 mm ± 10 mm.

K-3 PROCEDURE

The test is conducted as per the method given below:

a) An air flow with a THT concentration of 100 mg/m3 at a pressure of 0.1 ± 0.02 MPa is
passed through the pipe at a temperature of 23 ± 2 °C.
b) After 60 days of exposure an experienced observer has to detect the presence of THT
odour.

K-4 TEST REPORT

The test report shall include the following:

a) detection of THT odour;

b) delamination and leakage;
c) number, type and nominal dimension of the sample;
d) test temperature;
e) duration of the test;
f) any observation made during and after the test; and
g) any event able to influence the test results.

43
 ANNEX L
(Table 7)

RESISTANCE TO TENSILE LOAD ON JOINTS

L-1 PRINCIPLE

Samples of pipe/fitting joint are subjected to a tensile load in order to establish the short and
long term resistance to tensile loads.

L-2 SAMPLES

A sample consists of a pipe with two end fittings. One fitting shall have a possibility to
establish a pressure connection. The free length of pipe between the end fittings shall be 350
mm ± 10 mm.

L-3 PROCEDURE

L-3.1 Short-term (1 h) Test

The test is conducted as per the procedure given below:

a) Carry out testing at an ambient temperature of 23 ± 2 °C.

b) Put the test sample in the tensile testing machine.
c) Apply 3 kPa (0.03 bar) pressure and maintain it up to the completion of the test.
d) Raise the tensile load until the specified value for various classes as given in Table 7
has been attained, in such a way that the test piece is pulled at a speed of 0.1 l/min ±
0.05 l/min, where l is 350 mm.
e) Keep the tensile load constant for 1 h while monitoring the pressure.

L-3.2 Long-term (800 h) test

The test is conducted as follows:

a) Carry out testing at an ambient temperature of 23 ± 2 °C.

b) Put the test sample in a constant load apparatus.
c) Apply the load as given for various classes in Table 7.
d) Keep the tensile load constant for 800 h while monitoring the pressure.
e) For the short-term test, pressure inside the samples is monitored and any leakage
should be recorded along with the location and time of appearance.
f) For the long-term test, pressurise the sample after test period with a pressure of 3 kPa
(0.03 bar).
g) Check the sample for leakage.

L-4 TEST REPORT

The test report shall include the following:

44
a) type of the sample;
b) air pressure (initial pressure, pressure vs time plotting);
c) any leakage occurring during the phase (time of occurrence, strain/strength at the
moment of the leak, failure description); and
d) any problem during the test able to influence the result of the test.

45
 ANNEX M
(Table 7)

CRUSH TEST ON JOINTS

M-1 PRINCIPLE

Pipe crushing in the vicinity of a pipe joint is considered as critical. In order to determine the
resistance to crushing, a pipe sample is crushed very close to a pipe joint. After the test, a
tightness test is carried out.

M-2 SAMPLES

The test sample is made of an end-fitting, pipe and end-fitting and the joints are made in
accordance with the manufacturer’s instructions. The pipe length shall be 600 mm ± 10 mm.

M-3 PROCEDURE

The test is conducted as follows:

a) Perform a tightness test at 3 kPa (0.03 bar).

b) Apply a load on a plate (a square with 150 mm sides) positioned close to the fitting
(10 mm from the insert of the fitting or nut) to obtain a force level of 2 kN (see Fig.
8). This can be achieved in a tensile testing machine.

Alternatively, the plate can be a square with 75 mm sides and in that case a force
level of 1 KN shall be applied.

(All dimensions in millimetres.)

Fig. 8 Resistance to crushing close to fitting test assembly

c) Wait for the strain to be constant.

d) Check the tightness.
e) Perform a visual observation.
f) Control the test sample on tightness by applying a test pressure of 10 kPa (0.10
bar).

46
 g) Remove the load.
h) Measure the pipe diameter 5 min after removing the load and calculate the
remaining deformation.

M-4 TEST REPORT

The test report shall include the following:

a) number, type and nominal dimension of the sample;

b) test temperature;
c) crushing force;
d) duration of the test;
e) any observation made during and after the test; and
f) any event able to influence the test results.

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 ANNEX N
(Table 7)

IMPACT RESISTANCE TEST ON JOINTS

N-1 PRINCIPLE

The impact resistance of joints is determined by the impact of a falling striker of defined
dimensions and mass dropped from a defined height.

N-2 PIPE SAMPLES

The test sample is made of an end-fitting, pipe, coupling, pipe-end fitting. The joints are
made in accordance with the manufacturer’s instructions. Each pipe length shall be 1 000
mm ± 20 mm.

N-3 SHAPE AND MASS OF STRIKER

The striker shall have a spherical head with a radius of 10 mm and a mass of 5 kg (see Fig.
9).

Fig. 9 Impact resistance test assembly

N-4 PROCEDURE

The test shall be carried out as below:

a) Each end fitting is fixed on a motionless support.

b) Perform a tightness test at 100 kPa (1 bar).
c) Drop a striker from a height of 600 mm on the middle of the fitting
d) Perform a tightness test at 100 kPa (1 bar).
e) Check the sample for leakage by means of a foaming solution.

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N-5 TEST REPORT

The test report shall include the following:

a) leakage/no leakage;
b) name of the test;
c) number, type and nominal dimension of the sample; and
d) test temperature.

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 ANNEX P
(Table 7)

THERMAL CYCLING ON JOINTS

P-1 PRINCIPLE

To establish the negative influence of cycles of low and high temperatures, a sample of a
pipe with fittings will be subjected to a number of thermal cycles. The sample will be
pressurised. The leak rate is determined by measuring the pressure before and after the test.

P-2 SAMPLES

A sample consists of the combination of an end-fitting, pipe, coupling, pipe, end-fitting.

P-3 PROCEDURE

The test is conducted as follows.

a) The test samples shall be conditioned at a temperature of 0 °C for a conditioning time

greater than 1 h.
b) Pressurise the sample with a pressure of 10 kPa (0.01 bar) air pressure at 0°C.
c) Pressurise another sample with a pressure of 1.5 MOP with a minimum of 600 kPa (6
bar) air pressure at 0 °C.
d) Place the samples in an appropriate oven and apply the heat cycle as given in Fig. 10,
for N = 10 times.
e) Check the samples for leakage at 0 °C after the thermal cycling, measure the
pressure drop.

Key:
θ Temperature T time
θ1 −20 °C t1 (θ1 − θa) min
θ2 60 °C t2 t1 + 3 h
θa Ambient temperature t3 t2 + 90 min
a Rate of temperature change is 1 °C/min. t4 t3 + 3 h
t5 1 cycle, ~9 h

Fig. 10 Heat Cycle Layout

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P-4 TEST REPORT

The test report shall include the following:

a) Type of sample;
b) Type of Test;
c) Air pressure (initial pressure, pressure after thermal cycling);
d) Leakage/no leakage

51
 ANNEX Q
(Table 8)

REPEATED BENDING TEST

Q-1 PRINCIPLE

Using a special dimensioned mandrel, the resistance to repeat bending is determined of

samples from pipe fitting assemblies. After the bending procedure, the leak tightness is
determined.

Q-2 SAMPLES

The test sample is made of an end-fitting, pipe, end-fitting under 3 kPa (0.03 bar) test
pressure with one end fixed and the other end free.

Q-3 SPECIAL TOOLS

A special tool (spring or bending tool) can be used, if required.

Q-4 PROCEDURE

The test is conducted as follows:

a) The test sample should be put between two mandrels as shown in Fig. 11.
b) The mandrel radius is the minimum bend radius, that is, the pipe radius where the
minimum bend radius is declared by the manufacturer. The welded seam is on the
inside of the bend.
c) Bend the pipe from position A to position B. The time between positions A and B
should be around 10 s. Wait half a minute.
d) Put the pipe back into the position A.
e) Repeat steps (c) and (d) two times.
f) Check during the test if delamination of the layer has occurred.
g) Peel off the outer PE layer of the pipe and observe for any damage to the aluminium
layer.
h) The pipe may be rotated in different positions during examination to improve the
damage detection. Inspect visually for any delamination such as blisters, pitting and
notches.

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Key
A unbent position
B bent position
1 pipe longitudinal axis
2 air source; pressure sensor plug
3 end-fittings
4 mandrels
R bend radius
D minimum bend radius

Fig. 11 Repeated bending test assembly

Q-5 TEST REPORT

The test report shall include the following:

a) type of sample;
b) air pressure (initial pressure, pressure vs. time plotting);
c) any leakage occurring during the test (time of occurrence, number of bends done,
location);
d) any event during the test which could influence the result of the test.

53
 ANNEX R
(Foreword)

SUPPLY, PACKAGING, HANDLING, TRANSPORTATION AND INSTALLATION OF

MULTILAYER (PE-AL-PE) PIPE SYSTEMS FOR INDOOR GAS INSTALLATIONS

R-1 SUPPLY AND PACKAGING

R-1.1 The multilayer (PE-AL-PE) pipes shall be supplied either as self-supporting coils or,
straight length (either independent or bundled together), or as agreed between the supplier
and the purchaser. Their ends shall be cleanly cut, square with the axis of pipe and protected
against shocks and ingress of foreign bodies by appropriate end caps.

R-1.1.1 Coils

R-1.1.1.1 Multilayer (PE-AL-PE) pipes supplied in coiled form should be stored flat or
vertically in purpose-built racks or cradles, if desired by purchaser. Consideration should be
given for facilities, which avoid single point contact of the coils.

R-1.1.1.2 The dimensions of the coils shall conform to requirements given in 5.4.4. The
maximum width of any coil shall be 0.55 m. Maximum external surface temperature at the
time of coiling should not be more than 35 °C.

R-1.1.1.3 All coiled pipe shall be constrained in a stable configuration by banding with
PP/HDPE strap at least at three equispaced positions during production. The banding shall
be sufficiently stable to prevent movement.

R-1.1.1.4 Coiled pipe shall preferably be packed in woven fabric bags or wrapped with woven
fabrics. The fabric shall be of HDPE or PP, suitably compounded with 2.0 to 3.0 percent of
Carbon black or equivalent material to protect the pipe from damages and from UV
degradation.

R-1.1.2 Bundles

R-1.1.2.1 In case of multilayer (PE-AL-PE) pipes supplied in straight length bundled form, the
distance (X) between the supporting frames shall be equally spaced in order to allow
stacking (see Fig. 12). Such pipes shall rest evenly over their whole length. The supporting
frame shall not be nailed together and shall be constructed such as to lead the pressure load
directly through the supporting frame and not through the multilayer pipes.

R-1.1.2.2 The pipe bundles shall preferably be packed in woven fabric lay-flat tube or
wrapped with woven fabric. The woven fabric shall be of HDPE or PP, suitably compounded
with 2.0 to 3.0 percent of Carbon black or equivalent material to protect the pipe from
damages and from UV degradation.

54
 Fig. 12 Stacking Arrangement of Straight length pipes

R-1.2 Identification

Two labels of suitable dimensions shall be attached with each coils or bundles indicating all
information given in 9.2. Marking on labels shall be indelible.

R-2 HANDLING

R-2.1 General

The pipes shall not be dragged or thrown along the ground. In case handling equipment is
not used, appropriate techniques which are not likely to damage the pipe should be chosen.

R-2.1.1 Straight Pipe

Initial handling and storage of multilayer straight pipes should be made with the pipe in
packaged form, thus minimizing damage during this phase. When loading, unloading or
handling, it is preferable to use mechanical equipment to move or stack the packs.

R-2.1.2 Coils

Individual coils shall not be rolled off the edge of the loading platforms or trailers. These coils
may be kept on pallets and loaded, off-loaded using forklifts, pallet trolley etc.

R-3 TRANSPORTATION

R-3.1 Straight Lengths

When transporting straight multilayer PE-AL-PE pipes, use flat bed vehicles with a partition.
The bed shall be free from nails and other protuberances. The pipes or pipe bundles shall
rest uniformly in the vehicle over their whole length. The vehicles shall have side supports
appropriately spaced 2 m apart, and the multilayer pipes shall be secured effectively during
transportation. All posts shall be flat with no sharp edges. During transportation, the

55
multilayer pipes should be continuously supported such as to minimize movement between
the pipes and their supports. Also being relatively soft outer layer, poor handling techniques
may result in gauges, scratches, cuts or puncture.

R-3.2 Coiled Pipe

Coiled pipe may be supplied on pallets. The coils should be firmly strapped to the pallets,
which should in turn be firmly secured to the vehicle. There should be facilities to restrain
each coil securely throughout transit and the loading process.
To save on transport cost nesting of coils/straight length can be considered if agreed
between the purchaser and the supplier.

R-4 STORAGE

R-4.1 Pipes shall be stored in the manner to prevent damage from elevated temperature,
contact with chemicals, and prolonged exposure to direct sunlight. If the pipes are to be
stored outside, the recommendations on maximum storage time limits and maximum
temperature exposure shall be consulted from the manufacturers/or as per the
recommendations of the manufacturers. Non-ventilated covering of the pipe to protect it
against UV exposure may sometimes create excessive heat which may also be detrimental
to the pipe performance.

R-4.2 In case of outside storage, the cumulative exposure period should be determined with
reference to the pipe production code, which includes the date of manufacture. By using this
date, allowance is also made for exposure received during storage by the manufacturer.

R-4.2.1 It is recommended that multilayer pipes should not be stored outside for more than 2
years. Where individual pipe lengths and coils are stacked in pyramidal fashion, deformation
may occur in the lower layers, particularly in warm weather. Therefore, such stacks should
not exceed a height of 1 500 mm.

R-4.3 The multilayer pipes shall be stacked on a reasonably flat surface, free from sharp
objects, stones or projections likely to deform or damage them.

R-5 FIRST IN-FIRST OUT

In general, most manufacturers store the multilayer pipes outside prior to shipment. Issuing
from store on a ‘first in-first out’ can minimize the exposure time rotation with the extrusion
date used as control. The polyethylene pipe with the earliest extrusion date should be issued
for first installation.

R-6 INSTALLATION PROCEDURE

R-6.1 End Preparation for Jointing

End preparation should be done as below:

56
 a) Cutting of pipe ‒ Always use right pipe cutter to ensure burr free cutting. It is
necessary that the cut is always at the right angle. Hold the pipe firmly to ensure
the right angle cut.
b) Rounding of pipe ‒ Use suitable size of rounding tool to make the pipe is properly
rounded.
c) Chamfering of pipe ‒ Chamfer the end of the pipe so that O-ring is not damaged
during insertion.

R-6.2 Jointing Procedure using Brass Internal Sealing Fittings

The jointing using brass internal sealing fittings shall be carried out in the manner given
below (see also Fig. 13):

a) Fittings should be of the same make and compatible with the pipes to be joined.
b) Remove the nut and split ring from fitting. Ensure that O-rings in the fitting are in
good condition.
c) Place the nut and split ring over the pipe.
d) Insert the pipe fully inside the groove over the insert.
e) Push the split ring until it touches the shoulder of the fitting.
f) Tighten the nut fully using proper size spanner.
g) Use Spark Proof tools in case working near flammable gas installation.

Step 1: Prepare pipe edges. Step 2: Insert the fitting fully inside the pipe.

Step 3: Push the split ring until it

touches the fitting. Step 4: Tighten the nut fully.

Fig. 13 Jointing using Brass Internal Sealing Fittings

57
R-6.3 Bending Procedure

The following should be ensured while bending the pipes:

a) Use suitable internal/external bending spring (see Fig. 14).

b) Bending radius should be more than 5 times the outside diameter of the pipe.

Bending of Pipe with Internal Bending

Bending of Pipe with External Bending
Spring
Spring

External Bending Spring Internal Bending Spring

Fig. 14 Bending Spring

R-6.4 Clamping of Pipes

The following should be ensured while clamping the pipes:

a) Maintain the clamping distances as mentioned in the table.

b) Always support the fittings at all the joints.
c) Use proper clamps for supports.

Sl No. Pipe Size Horizontal Vertical

m m

(1) (2) (3) (4)

i) 14 0.80 1.00
ii) 16 0.80 1.00
iii) 20 0.80 1.00
iv) 25 1.00 1.00
v) 32 1.20 1.20
vi) 40 1.20 1.40
vii) 50 1.40 1.60
viii) 63 1.60 1.80

ix) 75 1.80 2.00

58
R-6.5 Testing of for Gas Tightness

The installation shall be tested for gas tightness as below:

a) Ensure that the installation is disconnected at the meter or from the cylinder.
b) Ensure all open ends are plugged or capped.
c) Ensure all gas appliances are isolated.
d) Connect a suitable test instrument.
e) Pressurize the consumer piping to 1.5 times the operating pressure (maximum can be
750 kPa).
f) Isolate the pressure source and allow a suitable period (say 2 min) for the temperature
of the testing medium within the consumer piping to stabilize.
g) Measure the loss of pressure during a test period of 5 min.
h) The pipe work can be considered gas tight and the test as satisfactory if there is no
loss of pressure during the test period of 5 min.

R-6.6 Concealing the Installation of PE-Al-PE Pipe

The installation of multilayer PE- AL-PE pipe shall be concealed in the following manner:

a) The pipe shall not be in contact with sharp objects.

b) The environment around it shall be non-corrosive to PE and material of fittings.
c) Fittings and joints shall be installed in suitable inspection chambers with covers
that are perforated or have slits over at least 20 percent of the chamber cover to
allow any gas to come out of the chambers.
d) There should be no annular space around pipes that are concealed.
e) If pipe is installed in a conduit, the annular space between the pipe and the
conduit shall be filled with inert material so that no gas can accumulate or pass
through the annular space.

59