UDC 656.56 621.644(21) 621 643.2 678.072.067.5-462

,

",..:..;.'-

:,g Brtish Standards InS1JtutJon. No pan of m,s publlcatJon may be pi'OtOCOPled or otnerwlse reproduced ~!he pnat perm,.ion In WntIng of BSI

Part 2. Pipelines on land: design, construction and installation

Canalisations. Code de bonne pratiquePartie 2. Canalisations terrestres: conception, construction et installationSection 2.5 Plastiques thermodurcissables renforces a la fibre en verre

Letfaden fr RohrleitungenTeil 2. Landverlegte Rohrleitungen: Bemessung, Konstruktion und VerlegungAbschnitt 2.5 Glasfaserverstarkte Duroplastrohre

BS 8010 : Section 2.5"

1989

Foreword

This Section of BS 8010 has been prepared under thedirection of :he Plastics Standards Policy Committee insupport of publication under the direction of the CivilEngineering and Building Structures Standards PolicyCommittee of BS 8010 in tour Parts to form a completerevision of all five Parts of CP 2010 as follows:

Part 1. Pipelines on land : generalPart 2. Pipelines on land : designo construction and

installationPart 3. Pipelines subsea : design, construction and

i nstallationPart 4. Pipelines on land and subsea : operation and

maintenancePart 1 (which supersedes CP 2010: Part 1 : 1966) contalnsgeneral information which is relevant to a variety ofpipelines and a variety of transported materials. It dealswith those aspects of pipeline devetopment that affect theowner and occupier of land through which the plpettnepasses.Part 2 is to be divided into severat Sections which are to bepublished as separate documents as follows:

Section 2.1 Ductile iron'Section 2.2 Steel (for water and assoclated products)Section 2.3 A'sbestos cement'Section 2.4 Prestressed concrete pressure plpellnes'Section 2.5 Glass reinforced thermosetting ptastlcsSection 2.6 ThermoplasticsSectlon 2.7 Precast concrete.Section 2.8 Steet (for oil. yas and assOClated products}

Each Section will contain information relevant to thedesign, construction and installation of a pipeline in theparticular material. These Sectlons wlll supersede Parts 2. 3.4 and 5 of CP 2010.Part 3 will include information relevant to the deslgn,installation and commissioning of subsea plpelines In steeland other materials.Part 4 will contain advice on the operatlon and malntenanceof pipelines. with Sections related to the conveyed material.This Section 2.5 does not supersede any part of CP 2010.It deats with pressure and non.pressure plpelinesconstructed using glass relnforced thermosetting plastlcsand in particular is based on plpes and fittings that complywith BS 5480 : Parts 1 and 2, as applicable.For supporting information not incorporated in publishedstandards, reference is made to a blbliography provlded asappendix C.I t has n!'en assumed in the draftlng of this British Standard

approprlately qualltled ano experlenceu p~ulJj~.Attention is drawn to the principal Acts of Parliamentenabling plpelines to be constructed and regulatingprocedures. glven In appendlx A of BS 8010 : Part 1.

Compliance with a Britlsh Standard does not ot Itseltconfer Immunlty from legal obligatlons.

t'UDllsnea

1989BS 8010 : Section 2.5

Contents

Page Page

Inside front coverBack cover

ForewordCommlttees responslble 8

89

1011

Subsection tour. Construction21 Transport, handling and storage22 Trenching23 Pipe inspection, repalr and cutting24 Laying, jointing and anchoring25 Backfilling

Code of practlce

Subsection one. General1 Scope2 Definitions3 Applications4 Safety5 I nspection

,

2223

Subsection five. Cleaning. testing andcommissioning26 Cleanlng27 Testing28 Commlssioning

121213

Subsection six. Abandonment29 Disused pipelines4

444444

13

141818

Subsection two. Materials6 General7 PiDes8 Fittings9 Valves

10 Flanges11 Bolts. nuts and washers12 Gaskets

AppendicesA Types of jointB Effect of non.metallic materials on water qualityC Bibliography of further readingD Typical summary of pipeline record s and of

any special arrangements for its maintenance 19

55566677

9151515161617

Subsection three. Deslgn13 Pipeline design14 Pipe desig"15 Service and environmental considerations16 Pipes on supports17 Access to pipeline18 Protective devices19 Joints20 External and internal corrosion resistance

Figures, Trench terminology2 Typical integral socket and spigot joint3 Typical loose collar joint4 Typical slip-on coupling5 Typical band coupling .6 Typical flange adapter7 Typical examples of various flanges

1

BS 8010 : Section 2.5 : 1989Code of practice. Subsection one

Subsection one. General

1 Scope 2.8 surge pressure. The maximum and minimum pressureproduced by a change in velocity of a moving stream ofliquido It is at its maximum when there is a sudden stoppagesuch as would be caused by suddenly closing a valve orstopping a pump.2.9 working pressure. The maximum sustained internalpressure excluding surge to which each portion of the

.pipeline may be subjected when installed.2.10 works hydrostatic test pressure. The internalhydrostatic pressure applied to pipes at the manufacturer'sworks.

3 Applications

This Section of BS 8010 gives design considerations andrecommendations for constructlon and installation ofpressure or non.pressure pipelines incorporating glassreinforced thermosetting plastlcs pipes and fittingscomplying with BS 5480 : Part 1 and Part 2 as applicable.It should be read in conjunction with BS 8010 : Part 1.This British Standard code of practice is not intended toreplace or duplicate hydraulic, mechanical or structuraldesign manuals.Descriptions of types of joints are given in appendix A andgeneral reQuirements for non-metallic materials likely tocome into contact with potable water are given inappendix B.NOTE 1 A list 01 documents recommended lor further readingfor additlonal informatlon and guidance is given inappendix C.NOTE 2. A lormat lor a tYP'cal summary lor pipeline records andmalntenance arrangements is given in appendix D.NOTE 3. The tltles 01 the publicatlons relerred to in this Sectlonare ',sted on the Inslde back cover

The pipelines covered by this Section of 8S 8010 aregenerally suitable for conveying water, sewage. trade waste.slurries. sludges, brine and some chemicals. When used forthe conveyance of sewage, referente should be made to8S 8005 : Parts O. 1, 2 and 4. G RP pipes and fittings areparticularly suitable for pipelines in locations wherecorrosive environments exist either internally or externally.

2 Definitions 4 Safety4.1 The recommendations of this Sectlon of as 8010 areconsidered to be adequate for public safety underconditions usually encountered in GAP plpelines, inctudingpipelines within towns, cities, water catchments andindustrial areas. Particular attention 15 called to the needto prevent damage or leakage arising from one or more ofthe following factors: .

(al corrosive 5011 condition;(b) internal corrosion/erosion;(c) mechanical equipment used durlng construction oron otherworks;(d) ground settlement, movement or erosion;(e) any abnormal circumstances. e.g. adjacent trenchlng.

4.2 Measures to prevent damage may Include one or moreof the fotlowing:

(al use of a particular resin type and/or an externalbarrler layer if necessary; '\(b) use of a particular resin typeiand/or an internalliner,if necessary, and limitation of flow velocity to reduceerosion;(c) providing increased cover"or a concrete cover as aprotection against extern,,' ."echar ;,.,,1 ~'7""'1'~ '1r

(dI for subsidence, additional flexible joints, ancnoreajoints, rafts or piling;(el indicating the presence of the pipeline withadditional markers, particularly in congested areas orareas where future development is known to be plannedand adequate marking at river and water coursecrosslngs;(f) providing protection from frost for pipelines aboveground or in ducts.

NOTE. The meanlngs 01 terms assocated wlth trenchlng are,llustrated In figure 1For the purposes of this Sectlon of BS 8010, the followingdefinitions apply.~.1 glass reinforced thermosetting plastics (GAP) plpe.A pipe conforming to BS 5480 and produced fromthermosetting resins reinforced with glass fibres anGpossibly containing inert filler and aggregate.

2.2 pipeline. A line of pipes, of any length, wlthoutfrequent branches. It does not include piping systems suchas process plant piping wlthin refineries, factories ortreatment planto2.3 flexible joint. A connectlon that is designed to permitangular deflections or axlal movement, or a combination ofboth, in service, without Impairing the efficiency of thejoint.I'JOTE. $ee appendlx A.2.4 rigid joint. A connectlon that is designed not to permitangular deflection or axial movement in service.NOTE. $ee appendlx A.2.5 self-anchoring joint. A connectlon that is designed toprevent separation under the axial thrust induced by

!(?rn,1i .," ." "" -r!. "~,,,,;...;' -'rnovementwhilst Stlll perl'nlt'Clng angular creTlectlon a~/..axial movement without impairing the efficiency of thejoint.NOTE $ee appendx A.2.6 site test procedure. The pressure to be applied to thepipeline, or sections thereof, after laying, to test Its strengthand watertightness.2.7 stringing- The placing of pipes in line on the groundr~ady for laying.

L

BS 8010 : Section 2.5 : 1Subsection one

5 I nspection

The integrity of a properly designed pipeline depends moreon the standards and quality of inspection applieo at allstages than on any other single feature.Particular emphasis is laid on the inspection for possibledamage to piDes, fittings and joints before installation andfor the correct bedding of the pipeline, jointing, anchoringand testing. Any sub-standard materials or workmanshipshould be rectified or, where necessary, rejected.

3

BS 8010 : Section 2.5 : 1989Subsection two

Subsection two. Materials

6 General 9.3 Air valvesAutomatic air valves are available in a number of forms,the most common being single orifice, double orifice andkinetic.

A variety of resin systems and reinforcement structuresmay be used to make GAP pipes and fittings that complywith the requirements of BS 5480 7P~~~~/_~!-!.-a!!..~?Different combinations will have differing properties whichmay make them particularly suitable for specific fields ofusage referred to In clause 3 (e,g. because they are capableof deflecting to a greater extent before their long termperformance is significantly Impalred, or because of betterresistance to cyclic stress or aggressive environments),and may be preferred accordingly,

7 PipesGAP pipes should comply wlth 8S 5480 : P~rt 1 andPart 2 as applicable.NOTE. These standards speclfy dlameters. lengths. classlfication,tolerances and baslc performance requlrements.

8 FittingsGAP fittings and relevant aspects of fittings made fromother materials should comply with BS 54BO : Part 1 andPart 2 as applicable.

1 O FlangesFlanges may be made from a variety of materials includingG RP or steel, but it is essential that those used arecompatible with the use of the pipeline. Flanges should becompatible with flanges as specified in BS 4504. Flangescomplying with other standards may be used for particularpurposes.Unless otherwise specified by the purd)aser, PN 16 flangesare usually supplied and are therefore suitable for workingpressures up to and including 16 bar, particularly for waterindustry applications. .

The use of high tensile bolts of smaller diameter than thecorresponding mild steel (MS) bolts to facilitatemanufacture and installation of larger diameter flanges ispermitted. BS 4772 gives details of the bolt hole diametersfor sud) flanges. Sud) flanges wlll be marked accordingly.Where high tensile bolts are used with flanges holed formild steel bolts, special washers should be used inaccordance with the pipe manufacturer's recommendations.

" Bolts, nuts and washersMild steel bolts and nuts should comply wlth therequirements of es 4190 and high tensile steel bolts andnt;ts should comply with es 3692 to mlnimum grade 8/8.Washers should comply with es 4320. Where the pipelineis in a corrosive environment. the bolts. nuts and washersmay require special coatings or other protectlon or to bemade from suitable alloy materials.

9 Valves9.1 MaterialsAII material used in valves should be compatible with theproducts which are to be conveyed in the pipeline. For usewith potable water. see the requrements given inappendix B.

12 Gaskets!f.; (;ontrol val vesValves should comply with the requirements of one of thefollowing British Standard speclfications:

(a) BS 5150 Cast iron wedge and double disk gate valvesfor general purposes;(b) BS 5152 Cast ron globe and globe stop and checl- DN) or more, to Ilmlt the stresses on the r;tlve SOil

23 Pipe inspection, repair and cutting

.;oJ11~,eu LV. I oe rila,1UlisClUle, S dU\I,;-e IOot LIe ~

sultable trench widths.

,,:;-; c 1.;"1,: -.."'.".. "

t'rior to Installation each plpe and joint should be visuallyinspected for signs of damage such as star cracking in thebore, grooving or scuffing and especially for damage tojoint surfaces,22.3 Trench beddlng

The trencn should be over-excavated to at least 100 mm toprovide a bedding under the pipe (see figure 1). The surfaceof the compacted bed should be continuous, smooth andfree of stones larger than those permitted in the contractspecification for the plpe zone backfill material, so as toprovide a uniform support to the pipe. The bed should beprovided with joint holes to ensure that the plpe rests onthe barrel and not on the joint.

23.2 RepairsBefore any repairs are carried out, the manufacturer'sadvice regarding the feasibility and procedures to beadopted should be sought. The recommendations givenBS 7159 may be applicable.

1989BS 8010 : Section 2.5Subsection tour

23.3 CuttingGRP pipes can be cut with a power-driven, abrasive-whee

24.3 Jointing plpes la id on gradientsIf plpeS ar,o laid down on steep or~dient~ ~...here the soil/pipr

~huulu~~uU!ll1ir&yGluII19'" J ",; JiJiedl~\ .ouseNOTE. When Ullng IUch equlpment the operatlve I1 requlred to_r IUltable eye protectlon 8nd Ihould W8ar a mask and gloves

excesslve splgot entry or v. ithdrawal OCCU;), A. soon as t,.,joint assembly has been made, the pipe should be held inplace and the trench backfilled ayer the barrel of the pipe.Unless the gradlent is 1 in 2 or steeper, anchorages are notnormally necessary. Where anchorages are necessary themanufacturer should be informed because this may affectthe design of the plpe,

23.4 End preparation of cut pipes for jointingBurrs and sharp edges should be removed by filing orgrinding ando where reQuired, a chamfer should be providedThe cut end should then be sealed. The manufacturer'sadvice regarding the dimensions of the chamfer and sealingof the ends should be adhered to.

24.4 Anchors and thrust blocksPipelines should be securely anchored at blank ends, tees,bends, tapers and valves to resist thrust arising frominternal pressure. Anchors and thrust blocks should bedesigned to withstand the forces resulting from the infernalpressure when the pipeline is under site test, taking intoaccount the safe bearing pressure of the surrounding soil.Consideratlon should also be given to forces in the pipelinewhen empty and precautions taken against possibleflotatlon. Where possibie, concrete anchor blocks shouldbe of such a shape as to leave the joint clear.Where fittngs are manufactured in GAP, they should becompletely encased in concrete. The dimensions and detalsof the concrete encasement should be such that it is capableof withstanding any internal pressure and external loadsappled to the piDe. This may require the use of reinforcedconcrete. Provision should also be made to resist thrust.For recommendatlons regarding GAP piDes encased inconcrete, see 24.5

24 Laying, jointing and anchoring

24.2 JolntlngJointing procedures will vary according to the type ofjoint being used.Basic requirements for all types of joint are as follows

(al cleanliness of all parts, particularly joint surfaces;(b) correct location of components;(c) centralization of the spigot within the socket;(d) strict compliance with manufacturer's jointingInstructlons.

The jointing surfaces should be cleaned for at least theInsertion depth. Gaskets should be wiped clean andinspected for damage. Where lifting gear has been used toplace the PiDe in the trench, it should be used to supportthe piDe and assist in centralizing the spigot in the socket.Where the plpeline is suspected to be subject to movementdue to ground settlement or temperature variation, a gapshould be left between the end of the spigot and thebottom of the socket to allow for tolerable changes ofdirection and/or length.

24.5 Building into structuresWhere GAP pipes enter manholes or pass through solidstructures, anchor blocks or valve chambers, or have aconcrete surround, it is essential to provide flexibility tothe pipeline on either side of the structure. This should beeffected by introducing two flexible joints to the pipelineon each side of the structure such that the first joint is nomore than one pipe diameter or 600 mm, whichever is thegreater, from the structure and the second is approximately1.5 diameters from the flrst. Care should also be taken toensure thorough compaction of the bedding materialbeneath the pipe immediately outside the structure,particularly where over-excavation of the trench hasoccurred. In some circumstances, it may be considereddesirable to backfill thls over-excavation with lean mixconcrete to the underside of the pipe bedding material.Where the pipe passes into the manhole, structure, orconcrete surround, the external surface of the pipe shouldbe surrounded with 6 mm to 10 mm thickness of a flexiblematerial, such as chloroprene rubber, for a minimumdistance of 100 mm from the point of entry into thestructure. Thls precautlon helps the plpe to absorb thestresses resulting from plpe deflections outside thestructure.Where watertightness between the pipe and structure is arequirement, pipes can be supplied with puddle flanges

24.1 LaYlngPiDes should at all times be handled with care in accordancewith the manufacturer's recommendations. PiDes should belowered into the trench uslng equipment suitable for theweight and size of piDes. The positioning of the sllng toensure a proper balance should be checked when the piDe isjust ctear of the ground. Where lifting equipment is notavailable, small dlameter plpes (normally 300 DN max.)may be lowered by hand using suitable rapes.AII persons should vacate the section of the trench intowhich the pipe is being lowered.AII construction debris should be cieared from the insideof the piDe before or just after a joint is mide. This can bedone by passlng a pull.through along the piDeS, or by hand,depending on the diameter of the piDe. When living is notin progress. a temporary end closure should be securelyfined to the open end of the plpeline. This can make thepipe buoyant in the event of the trench becoming floodedand any movement of the piDes should be prevented eitherby partial re.filling of the trench or by temporary struning.

BS BU 1 O : Secton 2.5Subsection tour

1989

laminated anta the pipe. Puddle flanges should not be usedto anchor tt-e pipes against thrust unless specifitcally

Where a change in direction is belng made by utilizing th,lateral deflection available from flexible joints, the tr..nrl

be treateu to 1m ,; v." rts bonli Nlth the concrete either bypainting with a suitable epoxy or other resin and blendingwith sand to glve a roughened surface prior to IncorporationIn the works, or by using bonding mortars, or a combinoatlon of these techniques. The piDe manufacturer's adviceshould be sought when determining suitable reslns

25 BackfillingReference should be made to BS 8010 : Part 1 for generalconsiderations regarding backfilling, clean-up andreinstatement. Wherever possible, in order to minimizemlsalignment of the bed with resulting shear acrosS thejoint, pipes should not have backfill material placed untilthe succeedlng plpe is laid and jointed. If joints are to beindlvidually Inspected during subsequent hydrostatictestlng, the trcnch should be backfilled and compactedover the barrel 01 each pipe leaving the joints exposed, orother such measures should be taken to prevent movementof the plpes during the testlng processes. Removal of anydewaterlng facilities should be scheduled in the light of theprevaillng condltlons so as to avoid any disturbance of thepipe by flotation before installation is complete.It is essentlal that the conditions of the materialsurrcundlng the pipes are as detailed in the designoBeddillg and the pipe zone materials should be compactedacross the fui! width 01 the trench and not disturbed bythe withdrawal of trench temporary support. Care shouldbe taken to fill and compact any voids left by thetemporary support system. $pecial attention should begiven to the compaction of the backfill material under thehaunches 01 the pi pe.

made wlth the plpes In Ilne, tne plpe tJ"ing deflected afterthe joint has been made. Deflectlon of any as.laid joinlshould not exceed the maxmum deflection recommendedby the manufacturer to allow for subsequent movemenl.Where high water tables are encountered, precautionsshould be taken to prevent flotation when the pipeline ISempty. Such precautions should not induce localized stressin the ppes.Where excavated material is to be used for the backfill,it should be selected to exclude organic material, frozensoil, large stones, rocks, tree roots or similar large objectsand should conform to the design requirementsWhere the native ground is fne grained, such as clay, silt orsand, or if the installation is below the water table, thebedding and pipe zone backfill material (see figure 1)selected should be such that fines will not migrate from theadjacent soil of the trench bottom or wall$. Conversely,the possibility of migration of fines from the pipe beddingand pipe zone backfill into the native soil should beminimized by the specification of material with a suitablegrading. In some instances the specification of a filterfabrlc may be an appropriate solutlon. Any migration ormovement of soil particles from one area to another mayresult in the loss of the necessary support for the pipe andsettlement.In the process of backfilling the trench, pipes should beprotected from falling rocks and direct Impact fromcompaction equipment.Heavy mechanical compactors should not be used within300 mm of the pipe crown.

85 8010 : 5ection 2.55ubsection five

1989

26 Cleaning should be calculated on the external spigot diameter andthe ancho,s designed to resist it. It is often economical to

: ~::I; ~.,; .i\_~ ..; a:.y..:o ""OU!j';OY a~ I.IU~~I"'t: tuensure that no foreign matter remains inside the pipe. Thefirst stages of the cleaning operation are referred to in 24.1and 24.2, i.e. cleaning individual pipes during laying andjointing. Pigs of suitable design, e.g. polyurethane swabs,may be used providing that the pipeline has beenconstructed to allow the passage of such pigs. Where thepipeline is to be tested with water, the filling and emptyingof the pipeline may to some extent cleanse the line.

27 Testing27.1 GeneralAII pipelines snould be tested before being brought intoservice. This should include testing for geometricalconditions, i.e. deflection of the overall position of thepipe and/or deformation of its cross-sectional dimensionsin excess of the applicable design limits, and forleaktightness. For the latter purpose, the type of test willdepend upon the fluid which the pipeline will eventuallyconvey and may comprise a hydrostatic test or apneumatic test, or both. The hydrostatic test is safer tocarry out and can be made more stringent as regards thestrength of a completed pipeline and it should be usedwherever practicable. With the exception of testing non-pressure mains at very low pressures (100 mm water gaugepneumatic testing is to be avoided if possible, because ofthe hazards inherent in containing large volumes ofcompressed air. However, there may be occasions whenhydrostatic testing is not possible and sir is the onlymedium available for applying a test pressure.

r.; ...el',.,'"f..' .e' ..r.ar: rJ~K ,iivv',""IO' UT tfl~ )LOP t:IIU:during testlng. Hydraulic jacks should be inserted betweentemporary anchors and stop ends if required in order totake up any horizontal movement of the temporaryanchors. AII permanent anchors (see 24.4) should be inposition and. if made of concrete. should have developedadequate strength before testing begins. The section undertest should be fillea with cJean disinfected water. takingcare that all air is displaced through vents at high pointsand at special stop ends or by using a pig or a sphere,After filling. the pipeline should be maintained at testpressure for a period Isee note) in order to achieveconditions as stable as possible for testing.If pressure measurements are not made at the lowest pointof the section, an allowance should be made for the statichead between the lowest point and the point ofmeasurement to ensure that the maximum pressure is notexceeded at the lowest polnt.NOTE The length of thls perloO will depend upon many factorssuch as movement of the plpelone under pressure. the quantlty ofa,r trapped and the degree 01 any re-roundlng by the Interna!pressure27.2.3 Test procedureNOTE, The follOWlng procedure os sultable for popelines carrYlngwater more strlngent requorements may be necessary for popelinescarrylng other fiulds

Site test pressures should be In accordance with 14.4.The pressure in the pipeline should be raised steadily untilthe s;te test pressure IS reached in the lowest part of thesection. Thls pressure should be maintained, by pumpingif necessary. for a period of not less than 1 h. The pumpshould then be disconnected and no further waterpermitted to enter the plpeline for a period of 1 h. At theend of this period the reduced pressure in the pipelineshould be measured. the original test pressure resto red bypumping and the loss measured by drawing off water fromthe plpeline until the pressure has fallen to match thereduced pressure previously noted,The acceptable loss should be clearly specified and the testshould be repeated until this is achieved. The generallyaccepted loss for non-absorbent pipelines such as GAP is0.02 L/mm of nominal bore per kilometre of pipeline per24 h per bar' of pressure applied head (calculated as theaverage head applied to the section under test). The lossshould be plotted graphically against time to show whenvolume changes due to such factors as re-rounding aresubstantally complete,27.2.4 Fault detect;on. If the test result is not satisfactory.the fault should be found and rectified.Methods employed for finding leaks include the following:

(a) visual inspection of pipeline, especially if each jointis not covered by the backfill;(b) aural inspection using a stethoscope or listening stickin contact with the ppeline;

27.2 Hydrostatic testing

27.2.1 General. The completed pipeline may be testedeither In one length or in sections; the length of sectionshould be decided by considering the following factors:

(a) availability of suitable water;(b) the number of joints to be inspected; and(c) the difference in elevation between one part of thepipel ine and another.

Where joints are left uncovered until after testing, eachpipe should be prevented from moving (see clause 25).27.2.2 Initial procedure. It is prudent to begin testing anyparticular pipel ine In comparatively short lengths,preferably as the pipeline is laid, and to increase the lengthof test section progressively as experience is gained untillengths of about 1.5 km or more are tested in one section,subject to consideration of the length of trench which it ispermissible to leave open in particular circumstances.Each test section should be properly sealed off, preferablywith special stop ends designed for the safe introductionand dlsposal of the test water and release of air, andsecured by adeQuate anchors. The thrust on the stop ends

.1 bar E 10' N/m' E 10' Pa

BS 8010 : Section 2.5Subsection five

1989

26 Cleaning should be calculated on the external spigot diameter andthe ancho,s designed 10 resist it. It is often economical to

; 1,:1:; ~'" .il_~ ..;..ia:.y u:o ''OIi~II'y a~ I.IV~~'u,t: tuensure that no foreign matter remains inside the pipe. Thefirst stages of the cleaning operation are referred to in 24.1and 24.2. i.e. cleaning individual pipes during laying andjointing. Pigs of suitable design, e.g. polyurethane swabs,may be used providing that the pipeline has beenconstructed to allow the passage of such pigs. Where thepipeline is to be tested with water. the filling and emptyingof the pipeline may to some extent cleanse the line.

27 Testing27.1 GeneralAII pipelines should be tested before being brought intoservice. This should include testing for geometricalconditions, i.e. deflection of the overall position of thepipe and/or deformation of its cross-sectional dimensionsin excess of the applicable design limits, and forleaktightness. For the latter purpose, the type of test willdepend upon the fluid which the pipeline will eventuallyconvey and may comprise a hydrostatic test or apneumatic test, or both. The hydrostatic test is safer tocarry out and can be made more stringent as regards thestrength of a completed pipeline and it should be usedwherever practicable. With the exception of testing non-pressure mains at very low pressures (100 mm water gaugepneumatic testing is to be avoided if possible, because ofthe hazards inherent in containing large volumes ofcompressed air. However, there may be occasions whenhydrostatic testing is not possible and air is the onlymedium available for applying a test pressure.

,-..el',,',.:.' .e'..i'.Jr:r;~Kliivvt:"I"IOlUTtflt:)tOPt:IIU:during testlng. Hydraulic jacks should be inserted betweentemporary anchors and stop ends if required in order totake up any horizontal movement of the temporaryanchors. AII permanent anchors (see 24.4) should be inposition and, if made of concrete, should have developedadequate strength before testing begins. The section undertest should be fillea with cJean disinfected water, takingcare that all air is displaced through vents at high pointsand at special stop ends or by using a pig or a sphere.After filling, the pipeline should be maintained at testpressure for a period tsee note) in order to achieveconditions as stable as possible for testing.If pressure measurements are not made at the lowest pointof the section, an allowance should be made for the statichead between the lowest point and the point ofmeasurement to ensure that the maximum pressure is notexceeded at the lowest polnt.NOTE The length 01 thl5 perloO will depend upon many lactorssuch as movement 01 the plpelone under pressure, the quantlty 01alr trapped and the degree 01 any re.roundlng by the Internarpressure27.2.3 Test procedureNOTE. The 101lOWlng procedure IS sultable lor plpel ones carrYlngwater more strlngent reQuorements may be necessary lor plpellnescarrylng other liuods

Site test pressures should be In accordance with 14.4.The pressure in the pipeline should be raised steadily untilthe site test pressure IS reached in the lowest part of thesection. Thls pressure should be maintained, by pumpingif ne~ssary, for a period of not less than 1 h. The pumpshould then be disconnected and no further waterpermitted to enter the plpellne for a period of 1 h. At theend of this period the reduced pressure in the pipelineshould be measured, the original test pressure restored bypumping and the loss measured by drawing off water fromthe pipeline until the pressure has fallen to match thereduced pressure previously noted.The acceptable loss should be clearly specified and the testshould be repeated until this is achieved. The generallyaccepted loss for non-absorbent pipelines such as GAP is0.02 L/mm of nominal bore per kilometre of pipeline per24 h per bar' of pressure applied head (calculated as theaverage head applied to the section under test). The lossshould be plotted graphically against time to show whenvolume changes due to such factors as re-rounding aresubstantially complete.27.2,4 Fault detection. If the test result is not satisfactory,the fault should be found and rectified.Methods employed for finding leaks include the following:

(al visual inspection of pipeline, especially if each jointis not covered by the backfill;(b) aural inspection using a stethoscope or listening stickin contact with the pipeline;

27.2 Hydrostatic testing

27.2.1 General. The completed pipeline may be testedeither In one length or in sections; the length of sectionshould be decided by considering the following factors:

(a) availability of suitable water;(b) the number of joints to be inspected; and(c) the difference in elevation between one part of thepipeline and another.

Where joints are left uncovered until after testing, eachpipe should be prevented from moving (see clause 25).27.2.2 Initialprocedure. It is prudent to begin testing anyparticular pipel ine in comparatively short lengths.preferably as the pipeline is laido and to increase the lengthof test section progressively as experience is gained untillengths of about 1.5 km or more are tested in one section,subject to conslderation of the length of trench which it ispermissible to leave open in particular circumstances.Each test section should be properly sealed off, preferablywith special stop ends designed for the safe introductionand dlsposal of the test water and release of air. andsecured by adequate anchors. The thrust on the stop ends

.1 bar = 10' N/m' .10' pa

BS 8010 : Section 2.5 :Subsections five and six

1989

28 Commissioning(c) use of electronlc listening devices. including leaknoise correlators which detect and amplify the soundof any escaping fluid;(d) use of a bar probe to detect signs of water In thevicinity of joints, if backfilled;(e) introduction of a gas compound into the test waterand use of a gas detectlon device to detect the presenceof any gas that has escaped through the leak.

Where there is difficulty in locating a fault, the sectlonunder test shouJd be subdivided and each part testedseparately.NOTE A pneumatlc test wlth an alr pressure not exceedlng 2 barigaugel may be used to detect leaks In plpellnes lald In waterloggedqround.Pneumatic testing could in the event of excessivepressurizatlon give rise to serious explOSlons. Durlng testlngit is important that all persons not engaged in the testoperations be kept away from the section of the pipelineunder test.Whenever pneumatic testing is carriedout the operatlonshould be supervised by a suitably trained englneer.27.2.5 Final testing. After all sectlons have been iointedtogether on completion of sectlon testing. a test on thecomplete pipeline should be carrled out. This test shouldbe carrled out in a manner similar to that describedin 27.2.1 to 27.2.4, as applicable. During the test, all workwhich has not been sublect to sectlonal tests should beInspected.27.2.6 Disposal of water. It is important to ensure thatproper arrangements are made for the disposal of waterfrom the pipeline after completlon of hydrostatic testlngand that all consents which may be required from landowners and occuplers. and from river drainage and waterauthorities have been obtained.NOTE. With some Ilqulds, notably 011 and 011 products, It may benecesserv to provlde temporarv nterceptors to prevent any 011being dlscharged wlth the weter In some cases, eg. heavllychlorlnated water, treatment may be necessary before fInal disposal.

28.1 GeneralPipelines intended to convey I iquids are usually testedhydrostatically. Unless the test water is of an acceptablequality for the purpose of the pipeline. commissioningconsists of displaclng the test water from the line by theliquid to be conveyed. Where the pipeline is to carrypotable water it should be sterilized as descrlbed in 28.2.Visible dirt and debris should have been removed eithermanually or by the use of cleaning pigs before testing(see 24.1 and clause 26). Filling and emptying the pipelinewith test water may also help deanse me line.Where air release and drainage valves have been installed.the test water may be drained and me pipeline refilledwith the I iquid to be conveyed.AII temporary connections used during the testing andcommissloning should be dosed off and securely blankedbefore the pipeline IS brought into use. AII blanks shouldbe sterilized where appropnate.28.2 SterilizationIf the pipeline is to carry potable water. where feasible itshould be thoroughly flushed with dean water. It shouldthen be disinfected by contact for 24 hours with watercontaining at least 20 mg/L of free d1lorine, emptied andfilled with potable water. The d1lorinated water shouldreceive treatment to dilute the d1lorine to an acceptablelevel before discharging to a sewer or watercourse. Aftera further 24 h. samples for bacteriological examinationshould be taken at a number of points along me pipelineand at all extremities.The pipeline should not be brought into service until thewater at each sampling polnt. having stood in the plpelinefor 24 h. has maintained a satisfactory potable standard.

28.3 R ecordsThe recommendations given In BS 8010 : Part 1concerning record plans should be adopted and shouldindude arrangements for maintenance of the plans toenable compliance with the corresponding recomrnend-ations given in Part 1 concerning abandonment. A formatfor a typical summary to detail commissioningarrangements is given in appendix D.

Subsection six. Abandonment

29 Disused pipelines

1 he recommendatons given in BS 8010 : Part 1 concerningabandonment should be adopted.

as 8010 : Section 2.5Appendix A

1989

Appendix A. Types ofjoint A.4 Type 4. Band couplingA.O I ntroduction A band coupling is designed for use wlth plain-ended pipes.

It consists of a metallic band encasing a shaped elastomericprofile. for example as shown in figure 5. The elastomericprofile is compressed by tightenlng up circumferentlal boltspositioned at one point on the circumference. Themanufacturer's advice regarding applicability, deflectionand withdrawal should be sought.

Joints are generally of a type using elastomeric sealing ringsas a medium. The most commonly used types of joint aredescribed in A.1 to A.6 and figures 2 to 7. Themanufacturer's recommended maximum joint deflectionsare intended to provide for changes in gradient and level,slow curves, the adjustment of angle at bends and anysubsequent movement. Deflections at installation shouldmake adequate allowance for any subsequent movement.

A.5 Type 5. Flange adaptersA flange adapter is designed to connect flanged pipe or anyflangeo fitting to plaln-ended plpe. It conSlsts of a flangeand sleeve piece, a wedge-shaped elastomeric gasket and a'cose gland fastened to the main body by bolts. Tighteningof the bolts compresses the gasket between the sleeve andpipe to seal the joint. for example as shown in figure 6.The flange joint is made using standard ;ointing proceduresfor flanged pipework. The adapter usually includes steelcomponents which should be suitably protected.Several designs are available and manufacturers. adviceregarding deflection and withdrawal should be sought.They do not provide the rigidity or anchorage of a standardflange joint and should be supported anclar anchoredaccordingly.

A.1 Type 1. Integral socket and spigot joint

A.2 Type 2. loose collar jointA loose collar joint is a simple push-in joint consisting of afull-width elastomeric profile, usually of an EPDM rubber',overwrapped with GAP. The elastomeric profile is bondedto the GAP wrapping and pipes are normally delivered withthe joint already jointed anta one end of the pipe, forexample as shown in figure 3. The joint can be used at anypoint along the length of a cut pipe without specialprofiling of the prpe end. The manufacturer's adviceregarding deflectlon and Wlthdrawals should be sought.

A.3 Type 3. Slip-on coupling

A.6 Type 6. Flange joints

A slip-on coupling s designed for use wlth plan-endedDlpes. I t conslsts of a sleeve, at the ends of which are wedgeshaped elastomeric gaskets and flanges held together bybolts, for example as shown in figure 4(a), Tightening ofthe bolts compresses the gaskets between the sleeve andPlpe to seal the joint.Specal slip-on couplings to connect pines of c!ifff!rA~.

coupllng IS shown In figure 4(b), but severa. ueslgns areavallable and advice should be sought from the manufacturerregarding applicability, deflection and withdrawal.

~

.ClaSSlficatlon In accordance Wlth es 3502 : Pan 3

1.4

An integral socket and spigot joint is a push-in jointincorporating a specially formed socket and spigot. Theseal is effected by means of an elastomeric gasket locatedon the spigot or in the soci

BS 8a10 : Section 2.5 : 1989Appendix A

lb) TYPlcal stepped slip-on coupllng

la'

TYPlcal stralght sllp-on coupling

Figure 4. Typical slip-on coupling

15

BS 8010 : Section 2.5Appendix A

1989

BS 8010: Section 2.5Appendix A

1989

tal Integral flange

b) GAP preformed flange 101n!

17

BS 8010 : Section 2.5Appendices B and C

1989

Appendix B. Effect 01 non-metallicmaterials on water quality

When used under the conditions for which they aredesigned, it is essential that non-metallic materials incontact with or likely to come into contact with potablewater are required to comply with the requirements ofBS 6920: Part 1.

Appendix C. Bibliography of further reading

These documents are I isted for information and guidance.The list should not be assumed to be crT1plete or exclusive.Where there are differences the advice of this Section ofBS 8010 should be followed or an engineer's decision taken.In addition, in respect of components to be used in apipeline, the manufacturer's literature should be included.AMERICAN SOCIETY OF CIVIL ENGINEERS. Buriedfiberglass pipe performance and installation requirementsand design calculations in international standardization.Proceedings of internacional conference 'Advances inunderground pipeline engineenng' University of Wisconsin,Madlwn, USA, August 27-29, 7985.ANSI/AWWA C 950-81 -Standard for Glass FibreReinforced Thermosetting Resin Pressure Pipe.ASTM O 2992-87 -Obtalning Hydrostatic Oesign Basls forReinforced Thermosetting Resin Pipe and Fittings.ASTM O 3839-79 Underground Installation of FlexibleReinforced Thermosetting Resin Pipe and ReinforcedPlastics Mortar Pipe.BAILEY, R.J., SCHLEGEL. O.L. and LAUGHLIN, B.E.Oeveloping concensus design approach for fibreglass-reinforced thermosetting pipe. Proceedings of 39thConference Reinforced Plastlcs/Composites Institute, USA,January 76- 79, 7984 rSesslon 75-6).

This document lar guldance on venlCUlar loaolng onlY

l~

BISHOP, R.R. and LANG, O. Oesign and performance ofburied fiberglass pipes -A new perspective. Proceedingsof the Pipeline Division Session, ASGE National Gonvention,1984.COLE, B.S. and TIMBLIN, L.O. Strain calculations forF RP pressure pipe. Proceedings of the Pipeline DivisionSession, ASGE International Gonference, New Orleans,March 30 -April 1, 1981.DEPARTMENT OF HEAL TH ANO SOCIAL SECURITY.The Bacteriological Examination of Water Supplies.DHSS Report 71.HYORAULICS RESEARCH L TO. Charts for the hydraulicdesign of channels and pipes. HMSO. Fifth edition, 1983.HYORAULICS RESEARCH L TO. Tables for the hydraulicdesign of pipes and sewers -Metric edition. HMSO. 198~.IRVINE, O.J. and SMITH, R.J.H. Trenching practice.GIRIA Report 97. 1982.NATIONAL WATER COUNCIL. ..\'ater supply hyglene.Occasional Technical Paper No. 2.REIO, I.W. GRP Sanitary sewer plpeS -Integral corroslon.resistant lining. GIRIA Report 112. 1982.WATER RESEARCH CENTRE ANO WATERAUTHOR ITIES ASSOCIA TION. Civil engineeringspeclfication for the water industry. Second edition 1984.WASTE WATER TECHNOLOGICAL ASSOCIATION e.B(ATV). Guidelines for static calculations of waste waterpipes and pipelines. A TV Worksheet A 127. December 1984.WRc ENGINEERING L TO. Guidelines to the waterindustry for the design and installation of glass fibrereinforced plastics pipes. WRc External report 31E. 1981.

WAc ENGINEERING L TO. Pipe Materlals SelectionManual -Water Mains -UK edition. WAc/WaterAuthorities Association, January 1988.YOUNG, O.C. and O'REILL Y, M.P. TRRL, DEPARTMENTOF TRANSPORT. A gUlde to design loadings for buriedrigid plpeS. HMSO 1983*.

BS 8010 : Section 2.5 : 1989Appendix D

Appendix D. Typical summary of pipeline records and of any special arrangements forits maintenance

Date of summary

We

submit the following summary of the testing and other records of the pipeline constructed by us to your contract

no.

1) Have been sampled and tested in accordance with BS 5480(COpy of manufacturlng certficates attached).

Glass reinforcedthermosettingplastics units

2) Pipes and other unlts have been laid with strength classes. joints and other manufacturingdetails in accordance with the contract specification and drawing nos.

Trench, tunneland beddingdetails

Have been constructed in accordance with the contract specification anddrawing nos.

Pipelinestraightness(Iine and level)

Have been checked for compllance vvlth the contract speclficatlon and drawing nos.by the followlng methods:

Pipeline watertightness initial tests

Method used

Infiltration rate achieved

Extiltratlon rate achleved

Pipeline watertightness final tests

Method used

I nfltratlon rate achleved

Exfltraton rafe acheved

Has been carried out in accordance wlth BS 8010 : Part 1 and Sectlon 2.5as applicable

Backtllllng, cleanlng-up and relnstatlng

Copies of certlfcates agreed wlth occupers attacheci

;)peClal arrangemefl"" Tur p'~ellne malnlenance

Arrangements have been made with landowners(see section five of BS 8010: Part 1 : 1989) as follows:

Slgned (l;ontraCtorl

LJate

19

Publications referred toBS 2494 Speclflcatlon for elastomerlc 10lnt rlngs for p'pework and plpelnesBS 3502 Schedule of common names ano abbrevlatlons for plastlcs and rubbers

Part 3. Aubbers anO latlcesBS 3692 Speclfcatlon for ISO metrlc preclSlon hexagon bolts, screws and nuts. Metric unltsBS 4190 Specflcatlon for ISO metrlc black hexaQon bolts, screws ano nutsBS 4320 Speclficatlon for metal wasners for general englneerlng purpOses -Metrlc seriesBS 4504 Speclllcatlon for flanges and boltlng lor pIDes, valves and flttlngs. Metrlc seriesBS 4772 Speclfcatlon for ductlle Iron pIDes and fittingsBS 4865 Speclficatlon for dimenslons of gaskets for pIDe flanqes to BS 4504BS 5150 Speclficatlon for cast Iron wedge and doubl.. dIsk gate valves lor general purposesBS 5152 Specification for cast iron globe and globe stop and check val ves lor general purposesBS 5153 Speclfcatlon for cast Iron check valves for general purposesBS 5155 Speclfcatlon for butterfly valvesBS 5163 Speclficatlon for predomlnantly key-operated cast Iron gate valves lor waterworks purposesBS 5480 Speclficatlon lor glass lIbre relnlorced plastlcs (GAP) piDes and littings lor use lor water supply or sewerage

Pan l. Dlmenslons, materlals and classlfcatlonPart 2. Deslgn and performance requlrements

BS 6920 Suitablllty of non-metall,c prOOucts lor use In contact wlth water Intended lor human consumptlon wlth regard to thelr elfecton the Quallty of the waterPart 1. Speclflcatlon

BS 7159 Code 01 practlce lor deslgn and constructlon 01 glass relnforced plastlcs (GAP) plplng systems lor Individual planu or SltesBS 8005 Sewerage

Pan O. Introductlon and gulde to data sources and documentatlonPan l. Gulde to new sewerage constructlonPan 2. Gulde to DumpIng statlons and DumpIng malnsPart 4. Gulde to deslgn and constructlon of outfalls

BS 8010 Code of practlce lor plPellnes ---o -Pan 1 P'pellnes on land General i~1tjt~,;6t,~.~;;,.r~ Code of practlce for p,pellnes' '" c ~ ,

Thermally Insulated underground plpng systems !;,(!itJ'~fZt~.~\f~;~~"J'*!~',"t.J?,!:~"., ~,'c} '.~,i:,~ t;i;,""."'",c

~~~

l.t' LU1UCP 3009

.Reterred to In the foreword only

BS 8010: Section 2.5: 1989Implementlng the standard, 01 necessary detalls such as symbOls andSlze, type or grade deslgnatlons EnQulrles should be addressed tothe Publicatlons Manager, BSI, Llnlord Wooo, Mllton KeynesMK14 6LE. The number lor telephone enQUlrleS IS 0908220027ano lor telex 825777.ContrKt requirements. A Brltlsh Standard does not purport toInclude all the necessary provlslons 01 a confract Users 01 BriflshStandards are responSlble for thelr correct appllcaflon

Revlsion 01 British Standards. Brltlsh Stanaaras are revlsed, whennecessary, 0'1 he IssUe elther 01 amendmenTS or 01 revlsed edltlonsIt is important that users of Britosh Stand.rds should aseertaon thatthey are in possessoon of the latest amendments or edotions.

Automatic updating service. BSI provldes an economlc, ,ndIvIdualand automatlc standards updatlnq serVlce calleci PLUS Detalls areavallable Irom BSI Enqulry Sectlon at ,.I,lton Keynes. Telephone0908 221166. telex 825777.

Inform8tion on all BSI publlcatlons IS In Tne 851 Cataloque.5pplemented each month by 851 New$ wntch IS avallable 10subscrlblng members 01 BSI and glves detalls 01 new publlcatlons.reVISlons, amendments and withdrawn standards Any person whowhen maklng use 01 a Britlsh Standard, encounters an Inaccuracy 01amblQulty, 15 requested to notlly BSI wltnout delay In arder 1hatthe matter may be Investlgated and approprlate actlon taken

This British Standard, havlng been prepared under the dlrectlon ofthe Plastlcs Standards Policy Commlttee, was publlshed under the;uthorlty of the Board of BSI and comes Into effect on31 Auqust 19B9

Britlsh Standards Instltutlon, 1989)BN O 580 17395 X

The fOllOWlng BSI references relate to the work on this standard:Commlttee relerence PLM/9 Draft for comment 86/44565 DC

Britiltl Standardllmtitution. Incorporated by Royal Chaner, BSlls~he Independent natlonal body for the preparatlon of BrltlshStandards. It IS the UK member 01 the Internar,onal Organlzatlonlor Srandardlzatlon and UK sponsor 01 the Brltish NarlonalCommlttee 01 the Inrernatlonal Electrotechnlcal Commlsslon.In addltlon to rhe preparatlon and promulgatlon 01 standards, BSIolfers speclallst servlces Including the provlsion 01 Inlormarlon:hrough rhe BSI Llbrary and Srandardline Database; Technlcal Help10 E xporters: and other servlces. Advlce can be obralned Irom theEnQulry Sectlon, BSI, Mltron Keynes MK14 6LE, lelephone0908 221166, telex 825777.Copyright. Users of British Standards are remlnded that copyrightsubslsts In all BSI publicatlons I~O parr 01 thls publlcatlon may bereproduced In any lorm wlrhout rIJe prIor permlsSlon In wrlrlnq ofas/. ThlS does not preclude the free use, In rhe course 01

Committees responsible for this Britsh StandardThe preparatlon of this Britlsh Standard was entrusted by thePlestlcs Standards POlicy Commlnee (PLM/-) to TechnlcalCommlttee PLM/9. upon whlch the followlng bodles wererepresented:

British Gas plcBritlsh Plastics FedaratlonBritish Plumblng F ittings Manufacturers' ASSOclatlonBritlsh Valva and Actuator Manufacturers' ASSoclatlonDepartment of the Environment tConstructlon Industrles

Directorate):Jepartment of the Envlronment IProperty Servlces Agency,Department of Transport~Iectrlcty Supply Industry In England and Wales~n9Ineer'ng EQulpment and Materlals Users AsSOclatlonHealth and Safety ExecutlveI nstitutlon of Civil EnglneersI nstltutlon of Gas Englneers

Instltution of Production EnglneersInstitution of Water and Environmental Management IIWEM}National Assoclatlon of Plumbing, Heating and Mechanlcal Servlces

ContractorsPlastcs and Rubber I nstitutePlastics Land Drainaga Manufacturers' AssoclatlonRoyal Instltute of Public Health and HygleneWater Authorities AssociationWater Cumpanlas AssoclationWater Research CentreThe follOWlng bodles were siso represented In he drafting of thestandard, through subcommlttees and panelsAssoclatlon of ConsultIng EnglneersBritlsh Board of AgrmentFederetlon of Civil Englneerlng ContractorsI nstl.utlcn of Mechanlcal EnglneersPipeline industries Gulld

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,~mendments ISSUed slnce publlcatlon

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