Standard Specification of MDPE Ball Valve

TECHNICAL VOLUME
INDRAPRASTHA GAS LIMITED (IGL)
TECHNICAL TENDER
FOR
SUPPLY OF MDPE FITTINGS & BALL VALVE
TENDER DOCUMENT NO: xxxxxxxxxxx
VCS REFERENCE NO: xxxxxxxxxxxx
(VOLUME II)
A 17.03.2017 ISSUED FOR REVIEW & COMMENT

Rev Date Description Author Checked Approved
Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 1 of 30

SUPPLY OF MDPE FITTINGS & BALL VALVE
TABLE OF CONTENTS
SI.
DESCRIPTION DOCUMENT NO. REVISION
NO.
1 MATERIAL REQUISITION A
2 TECHNICAL SPECIFICATION FOR FITTINGS A
TECHNICAL SPECIFICATION FOR BALL

3 A
VALVES

MATERIAL REQUISITION
FOR
FITTINGS AND BALL VALVE

MDPE FITTINGS & BALL VALVE
INTRODUCTION:
Indraprastha Gas Limited (IGL) is a joint venture company of M/s Gas Authority of India Limited
(GAIL), M/s Bharat Petroleum Corporation Limited (BPCL) and Govt. of National Capital Territory of
Delhi (NCT). IGL supplies Natural Gas to domestic & commercial consumers in NCT of Delhi and
NCR. IGL wants to augment their PNG network.
VCS Quality Services PVT LTD. is an inspection service provider across various industry sector. VCS
is now inviting tender for procurement of MDPE Fittings & Ball Valve in NCT of Delhi and NCR.
This document covers the technical specification for the enquiry.
SCOPE OF SUPPLY:
S. No. Material Description UOM Total Quantity
A MDPE Ball Valve

1 MDPE BALL VALVE 63 EF END (WITHOUT STEM) NO 3962
2 MDPE BALL VALVE 125 EF END (WITHOUT STEM NO 339
3 MDPE BALL VALVE 180 EF END (WITHOUT STEM NO 250
4 MDPE BALL VALVE 32 EF END (WITHOUT STEM) NO 0
B MDPE Bends
1 MDPE BENDS 63 MM OD 90 DEG PE80/100 NO 1520
2 BEND MDPE 125 X 90 DEG PE80/ PE 100 NO 942
3 BEND MDPE 180MM 90 DEG. PE80/ PE100 NO 832
4 MDPE BENDS OF SIZE 63 MM OD OF 45 DEGREE NO 0
5 BEND MDPE 125 X 45 DEG PE80/ PE100 NO 0
6 BEND MDPE 180MM 45 DEG PE80/ PE100 NO 0
C MDPE Coupler
1 COUPLER MDPE 20MM OD PE80/ PE100 NO 0
5 COUPLER MDPE 180MM PE80/ PE100 NO 16584
D MDPE Saddle
1 SADDLE TAPP. MDPE 63X20MM PE80/PE100 NO 0
4 SAD TAP. MDPE 125X63MM PE80/PE100 W CPLR NO 0

TECHNICAL SPECIFICATION FOR MDPE
FITTINGS

7 SAD TAP. MDPE 180X63MM PE80/PE100 W CPLR NO 0
8 REDUCER MDPE 180X125 PE80/PE100 WTH CPLR NO 0
E MDPE Reducer
F MDPE Equal Tee
1 EQUAL TEE MDPE 20MM PE80/PE100 WITH CPLR NO 0
2 EQUAL TEE MDPE 32MM PE80/PE100 WTH CPLR NO 0
G MDPE End Cap
1 END CAP MDPE 20MM EF END PE80/ PE100 NO 0
H MDPE Transition Fittings
1 TR. FITTING PE TO CS 32MM X 1" PE80/100 NO 0
2 TRANSITION FITTING PE TO GI 32MM TO 3/4" NO 1039
4 TR. FITTING PE TO CS 125MM X 3 PE80/100 NO 20
6 TR. FITTING PE TO SS 20MM X1/2" PE80/100 NO 20155

FITTINGS
TECHNICAL SPECIFICATION
FOR
MEDIUM DENSITY POLYETHLENE FITTINGS

FITTINGS
CONTENTS
1. SCOPE AND FIELD OF APPLICATION
2. REFERENCES
3. SYMBOLS & DEFINITIONS
4. DESIGNTION
5. DESIGN
6. ELECTRICAL CHARACTERISTICS
7. DIMENSIONAL
8. PERFORMANCE REQUIREMENTS
9. MARKING
10. PACKAGING

FITTINGS
1.0 SCOPE AND FIELD OF APPLICATION
This specification along with applicable codes and standards describes the minimum
requirements for design, selection, manufacture, inspection/ testing and supply of "MDPE
FITTINGS".
This specification elaborates the requirements for Electrofusion fittings in the nominal size
range 16 to 180 mm made from PE compound used with PE pipes for supply of natural gas
and to be used at operating pressure 4.0 Bar(g) & operating temperature 25C.
The material grades to be used are PE80 / PE100.
The bidder shall highlight any conflict before finalizing the offer and purchasers decision shall
be final in this regard.
Compliance with this specification shall not relieve the vendor of the responsibility of
furnishing equipment and auxiliaries of proper design, material and workmanship to meet
specified operating conditions.
ELECTRO FUSION FITTING JOINTING
1.1 For Electro Fusion fitting jointing an electrical resistance element is incorporated in the socket
of fitting which when connected to an appropriate power supply, melts and fuses the
materials of the pipe and fitting together.
1.2 The effectiveness of this technique depends on attention to the preparation of the jointing
surfaces, in particular the removal of the oxidized surface of the pipe over the socket depth
and ensuring the jointing surface are clean. If ovality causes gap between concentrically
located pipe and the fitting to exceed 1% of the pipe OD after re-rounding to ensure correct
welding. If the gap still exceeds 1% of the pipe OD after re-rounding, then a check should be
made of the pipe OD dimensions to determine if it meets specification.
1.3 The maximum gap between eccentrically located pipe and fitting i.e. pipe touching fitting at
one point must not exceed 2% of the pipe OD.
1.4 Sometimes coiled pipes may be too oval to fit into couplers or the end of the pipe may make
the alignment of the ends impossible. In such circumstances, the use of a mechanical pipe
straightener or rounding tool is necessary.

FITTINGS
2.0 REFERENCES:
prEN 1555-1: Plastics piping systems for the supply of gaseous fuels- Polyethylene (PE) -
part 1: General
part 3: Fittings
part 7: Guidance for assessment of conformity
ISO CD 12176-4: Plastics pipes and fittings - Equipment for fusion jointing polyethylene
system - part 4: Traceability coding
ISO TR 13950: Plastics pipes and fittings - Automatic recognition systems for Electro fusions.
3.0 SYMBOLS & DEFINITIONS
3.1 SYMBOLS FOR ELECTRO FUSION FITTINGS
3.1.1 SYMBOLS FOR ELECTRO FUSION SOCKET FITTINGS
The dimensions and main symbols used in this part of ISO 8085 are shown in figure 1,
where,
D1 is the mean inside diameter in the fusion zone comprising the mean inside diameter
measured in a plane parallel to the plane of the mouth at a distance of L3 + 0.5 L2 from the
plane at the mouth.
D2 is the minimum bore comprising the minimum diameter of the flow channel through the
body of the fitting.
L1 is the depth of penetration of the pipe or of the male end of spigot fittings.
L2 is the nominal length of the fusion zone corresponding to the heated length.
L3 is the nominal unheated entrance length of the fitting comprising the distance between the
mouth of the fittings and the near end of the fusion zone.

FITTINGS
3.1.2 SYMBOLS FOR ELECTRO FUSION TAPPING TEES
The main symbols used for tapping tees are shown in Figure 2, where,
h is the height of the service pipe and comprising the distance between the axis of the main
pipe and the axis of the service pipe.
L is the width of the tapping tee and comprising the distance between the axis of the main
pipe and the plane of the mouth of the service pipe.
H is the height of the saddle which, comprises the distance from the top of the main to the top
of the tapping tee or saddle.

FITTINGS
3.2 DEFINITIONS
3.2.1 Geometrical Definitions
a) Nominal diameter (dn / do):
The nominal diameter is taken as the nominal outside diameter of the corresponding pipe
series.
b) Nominal wall thickness (en):
The nominal wall thickness is taken as the nominal wall thickness of the corresponding pipe
series.
c) Mean inside diameter:
The arithmetic mean of at least two inside diameter measured at right angles to each other in
transverse planes.
d) Out of roundness of the Socket:
The maximum inside diameter minus the minimum inside diameter of the socket, measured in
the same plane, parallel to the plane of the mouth.
e) Maximum out of roundness of the socket:
The greatest value of the out of roundness between the plane of the mouth and a plane
separated from it by a distance L1.
f) SDR value for a fitting:
The SDR value for a fitting is taken as being the same as that for the corresponding pipe
series.
Where, SDR = dn/en
g) Wall thickness (E) of a fitting:
The wall thickness of a fitting at any point of the body of the fitting which could be submitted
to a stress inducted by the pressure of the gas in the piping system.
3.2.2 Material Definition
a) Virgin Material:
Materials in form such as granules or powder that has not been subjected to use or
processing other than that required for its manufacturer and to which no reprocessable or
recyclable materials have been added.

FITTINGS
b) Own Reprocessable Material:
Material prepared from rejected unused pipes, fittings or valves, including trimmings from the
production of pipes, fittings or valve, that will be reprocessed in a manufacturers plant after
having been previously processed by the same manufacturer by a process such as injection
moulding or extrusion.
c) Compound:
A homogenous mix of base polymer (PE) and additives, i.e. antioxidants, pigments, UV-
stabilizers etc, at a dosage level necessary for the processing and of components of this
standard. The additives shall not have a negative influence on the performance with respect
to feasibility. All additives shall be uniformly dispersed.
3.2.3 Definition related to Material Characteristics
a) Lower Confidence Limit (LCL):
A quantity with the unit in mega Pascals (MPs), which can be considered as a property of the
material representing the 97.5% lower confidence limit of the predicted long-term hydrostatic
strength at a temperature 20 C for 50 years in water.
b) Overall Service (Design) Coefficient (C):
An overall coefficient with a value larger than 1.0, which takes into consideration service
conditions as well properties of the components of a piping system other than those
represented in LCL. For gas applications, C can have any value equal to or greater than 2.0.
c) Minimum Required Strength(MRS):
The value of the LCL rounded down to the next lower value of the R 10 series when the LCL
is less than 10 Mpa or to the next lower value of the R 20 series when the LCL is greater than
or equal to 10 Mpa.
Note: R10 and R 20 series are the Renard number series according the ISO 3 and ISO 497
d) Melt Mass Flow Rate (MFR):
A value related to the viscosity of the molten material at a specified temperature and rate of
shear.
3.2.4 Definitions Related to Service Conditions
a) Gaseous Fuel:
Any fuel, which is in the gaseous state at a temp. of + 15 C and a pressure of 1 bar.
b) Maximum Operating Pressure (MOP)

FITTINGS
The maximum effective pressure of the gas in the piping system, expressed in bar, which is
allowed in continuous use. It takes into account the physical and the mechanic characteristics
of the components of a piping system.
MOP = (20 x MRS) / (C x (SDR-1)).
3.2.5 Definition on Design of Electrofusion Fittings:
a) Electro fusion Socket Fitting:
A polyethylene (PE) fittings which contains one or more integral heating elements, that are
capable of transforming electrical energy into head to realize a fusion joint with a spigot end
or a pipe.
b) Electrofusion Saddle Fitting:
A polyethylene (PE) fitting (top loading or wrap around) which contains one or more integral
heating elements, that are capable of transforming electrical energy into head to realize a
fusion joint onto a pipe.
c) Tapping Tee:
An Electro fusion saddle fitting, which contains an integral cutter, to cut through the pipe wall.
The cutter remains in the body of the saddle after installation.
d) Branch Saddle:
An Electro fusion saddle fitting, which requires an ancillary cutting tool for drilling a hole in the
adjoining main pipe.
e) U Regulation:
Control of the energy supplied during the fusion process of an Electrofusion fitting, by means
of the voltage parameter.
f) I Regulation:
Control of the energy supplied, during the fusion process of an Electrofusion fitting by means
of the current parameter.

FITTINGS
4.0 DESIGNATION
4.1 Fittings shall be designed according to the grade of material, nominal diameter and Standard
Dimension Ratio (SDR).
4.2 GRADE OF MATERIAL:
4.2.1 Fittings shall be classified according to grade of material, as given in following table:
TABLE 1
M.R.S. LCL (200C, 50Yrs 97.5%) Maximum Allowable
Material
Mpa Mpa Operating Pressure
PE 80 8.0 8.00< LCL < 9.09 5.5 bar
PE 100 10.0 10.00< LCL < 11.19 7.0 bar
4.3 NOMINAL DIAMETER:
The Nominal Diameter for fittings covered in this standard are 16, 20, 25, 32, 40, 63, 75, 90,
110,125, 140, 160 ,180 mm.
4.4 MATERIAL
4.4.1 Polyethylene Compound:
The Polyethylene compound used in the manufacture of fitting shall be a cadmium free
compound.
It shall be free from visible water, shall comply with the requirements as specified in Table-2.
TABLE-2: CHARACTERISTICS OF PE COMPOUND
Characteristics Units Requirements Test Test Methods

parameters
Conventional Kg/m3 >930 (base polymer) 230C ISO 1183-ISO 1872/1
Density
Melt mass Flow g/10min + 20% of value 1900C ISO 1133
rate nominated by condition 18
compound producer
Thermal Stability Minutes > 20 2000C (2) ISO TR 10837
Volatile Content at mg/kg <350 ISO 4437 Annex. A
extrusion
Water Content (3) mg/kg <300 ASTM D 4019
Carbon black % (m/m) 2.0< ..<2.5 ISO 6964
Content
Carbon Black Grade <3 ISO DIS 11420
Dispersion (4)

FITTINGS
Characteristics Units Requirements Test Test Methods

parameters
Pigment Dispersion Grade <3 ISO DIS 13949
(5)
Resistance to Gas h >20 800C 2 Mpa ISO 4437 Annex. B
Constituents
Resistance to rapid Mpa The critical pressure 00C ISO DIS 13478
crack propagation in the FS test shall be
(RCP) (6) greater than or equal
to the value of the
Full Scale (FS) test: MOP of the system
d 250mm multiplied by 1:5
Or
S4 Test : in Mpa The critical pressure 00C ISO DIS 13477
principle according in the S4 test shall be
to all diameters(7) equal to or greater
than the value of
MOP of the system
divided by 2.4 (8)
Resistance to slow h 165 800C, 8.0bar ISO DIS 13479
crack growth en > (f) (9)
5mm 800C, 9.2bar
(f) (10)
.
1) Non black compound shall conform to the weathering requirements to ISO 4437.
2) Test may be carried out at 210C providing that there is a clear correlation to the results at
200C, in case of dispute the reference temperature shall be 200C.
3) Only applicable if the compound does not conform to the requirement for volatile content. In
case of dispute the requirements for water content shall apply.
4) Carbon black dispersion for black compounds only.
5) Pigment dispersion method for non-black compounds only.
6) Only applicable for fittings which incorporate extruded pipe elements.
7) Shall be performed on pipe with a wall thickness of >15 mm.
8) This factor 2.4 is still under study and may be subject to change. If the requirement is not
met, then retesting by using the Full Scale (FS) test shall be performed.
9) Test parameter for PE 80.
10) Test parameter for PE 100.

FITTINGS
5.0 DESIGN
Fittings shall be designed for system operation at the pressures given in Table 1.
Fittings shall be free from cracks, voids, blisters, distortion, dent or other defects.
Fittings shall be capable of being fusion jointed to pipes using control boxes. The fittings
shall exhibit the strengths and fusion compatibility with, pipes of respective sizes.
Each fitting shall be bar coated and shall have a permanent fusion indicator.
Heating coil design shall be such that it should not be damaged during assembly leading
to short circuit of heating coil.
5.1 ELECTROFUSION SOCKET FITTINGS
Electrofusion Socket Fittings shall incorporate a method of controlling pipe penetration within
each socket. The inner cold zone of each socket shall not be less than (0.1 d + 5) mm for
sizes upto 125 mm & 0.1 d for sizes greater than 125 mm.
5.2 TAPPING TEES
Tapping tees shall be capable of installation by a force between 1 kN and 1.5 kN applied from
above and on the centre line of the tapping tees stack. The tapping tees shall provide a
means of cutting through the pressurised main pipe and allowing the gas flow into the outlet
pipe.
5.3 TRANSITION PIECES
To make connection between steel pipe and MDPE pipe specially fabricated transition pieces
consisting of steel and MDPE pipes should conform to the requirements mentioned herein.
5.3.1 MDPE Pipe:
The MDPE pipe with one end plain should conform to the specification (IS:14885/ SDR 11).
5.3.2 Steel pipe
Black ERW steel pipe should conform to the specifications as laid in API STD 5L (latest
revision).
5.3.3 Pipe End
One end of the pipe should be beveled for welding angle of bevel should be 30 + 5.
5.3.4 Jointing between Steel and MDPE Pipes:

FITTINGS
Steel and MDPE pipes should be so jointed in the factory so as to have a monolithic joint
which is leak free and should be mechanically as strong or stronger than the PE Pipe.
5.4 TRANSITION FITTINGS (MDPE PIPES TO THREADED G.I. FITTING)
Transition fitting for jointing of MDPE Pipes confirming to specification IS:14855/ SDR 11 to
threaded G.I. tubing confirming to specification. The MDPE end of the transition fitting shall
be jointed with MDPE Pipe with the electrofusion method.
The transition fittings shall be bar coded electrofusion type for PE connection, NPT Female
threading confirming to ANSI B 20.1 for G.I connection & butt welded for carbon steel end.
The carbon steel material of transition fittings shall be confirming to APL 5L.
6.0 ELECTRICAL CHARACTERISTICS
For each size and type of fitting, the manufacturer shall declare the nominal resistance of the
heating element and specify the production tolerances.
The manufacturer shall demonstrate that satisfactory joint can be made using the extremes of
these tolerances.
All fittings shall have mechanically shrouded. The fittings terminals connections shall be
suitable for use with voltage less than or equal to 48 volts. Considerations should be given to
the design of the shroud with respect to impact damage. When hollow terminal pins are used,
the hole at the top of the pin shall be less than 1 mm diameter. The terminal pin material shall
be corrosion resistant and the surface finish shall be N7.
Fittings incorporation two electrofusion sockets shall have both sockets fused in a single
operation.
The heating elements shall be suitable designed to prevent short circuiting or local
overheating/ under heating during the fusion operation. Protective coating applied to the
heating element shall not have a detrimental effect on the joint.
The heating element wire shall not be disturbed during assembly.
7.0 DIMENSION
7.1 MEASURING TEMPERATURE
Fittings shall not be measured within 24 hrs. of manufacturer to allow for normalization. The
fittings shall be measured at an ambient temperature of 23 + 2C, after a conditioning period

FITTINGS
of 5 Hrs. Methods of measurements shall provide the appropriate degree of accuracy, and
the reference conditions specified in this clause apply in case of disputes in dimensional
measurement.
7.2 DIMENSIONAL STABILITY
7.2.1 Couplers (Including all forms of socket fittings)
All coupler dimensions shall conform to their specified value when the fitting has been stored for a
period of 12 months at a temperature of 30 + 2C.
7.2.2 Tapping Tees and Branch Saddles:
All tapping tee and branch saddle dimensions shall conform to their specified agreed values when
the fitting has been stored for a period of 12 months at a temperature of 30 + 2C.
TABLE-3: SOCKET DIMENSIONS
Pipe Size Limits for average diameter d on Apparent fusion Penetration depth
d (mm) each fitting measured over length L (mm) L (mm)
apparent fusion length L (mm)
Maximum Minimum Minimum Maximum
16 16.6 16.4 15 41
20 20.6 20.4 16 41
25 25.6 25.4 18 41
32 32.9 32.5 18 41
40 41.0 40.6 18 49
50 51.1 50.7 20 55
55 56.1 55.7 21 63
63 64.1 63.7 23 63
75 76.3 75.9 25 70
90 91.5 91.1 28 79
110 111.3 111.1 32 82
125 126.7 126.2 35 87
140 141.7 141.2 38 92
160 162.1 161.4 42 98
180 182.1 181.5 46 105
Notes:
1. The apparent fusion length, L, is the length of the integral heating elements, from
the first regular section of the element to the end of the regular section, on one
side of the fitting. This dimension to be measured from outside edge to outside
edge of wire.
2. Any protrusions into the bore of the fitting (e.g. centralization ribs) shall not

FITTINGS
prevent easy assembly in the field.
3. The overall length of a straight coupler is equal to twice the quoted maximum
penetration depth L.
TABLE-4: OVERALL LENGTH OF REDUCERS
Major Diameter Maximum Length

(mm) (mm)
25 90
32 90
63 120
90 180
125 215
180 280
TABLE-5: BRANCH SADDLE ASSEMBLY OUTLET LENGTH
Off-take Shut-Off Dimension from flange Dimension from pipe end to

size mm method face to crown of main crown of main
Class B Class B Class B Class B
fitting mm fitting mm fitting mm fitting mm
63 Valve - - - -
63 Squeeze - 260* - -
90 Valve - - 400 -
90 Squeeze 400 180** - -
125 Valve - - 550 -
125 Squeeze 360 180*** - -
180 Valve - - 750 -
180 Squeeze 360 180+ - -
* Flange size DN 50
** Flange size DN 100
*** Flange size DN 150
+ Flange size DN 250
8.0 PERFORMANCE REQUIREMENTS
8.1 MECHANICAL CHARACTERISTICS
Fittings shall be tested using pipes, which conform to ISO 4437. Test samples shall be
assembled in accordance with ISO DIS 11413. Following the technical instruction of the
manufacturer and using fusion equipment conforming ISO DIS 12176.2.

FITTINGS
When tested in accordance with the test methods as specified in Table 6 using the
indicated parameters, the fittings have mechanical characteristics confirming to the
requirements given in Table 6.
TABLE -6: MECHANICAL PROPERTIES
Characteristics Units Requirements Test Parameter Test method

Hydrostatic H Failure time >100 End caps Type a) free 1 h ISO DIS 9356
strength at 20C orientation 9 Mpa, 12.4 Mpa,
conditioning 20C
time. Type of
test
circumferential
(hoop) stress
pipe PE 80, PE
100, Test
temperature.
strength at 80C orientation water-in-water
conditioning 4.6 Mpa 5.5 Mpa
time. Type of 80C
test circum-
ferential (hoop)
stress pipe PE
80, PE 100, Test
temperature.
strength at 80C orientation water-in-water
conditioning 4 Mpa, 5
time. Type of Mpa, 80C
test circum-
ferential (hoop)
stress pipe PE
80, PE 100, Test
temperature.
Cohesive mm Length of initiation Test 23C ISO 13954 (A)
resistance of brittle fracture temperature ISO 13955 (A)
L/3 choice of ISO 13956 (B)
method
Impact strength No failure Test 20C ISO DIS 13957

(B) No leakage temperature 23C
Falling height 5m
Mass of the 5kg
striker
Pressure drop M3/h 0.5 mbar : dn < 63 Air flow rate Indicated by the PrEN 12117
(B) 0.1 mbar : dn2 > 63 Test medium manufacturer
Test pressure Air source 25
mbar

FITTINGS
(A) Electro Fusion Socket Testing
(B) Tapping Tees

For hydrostatic strength test at 80C only brittle failure shall be taken into account. If ductile
failure occurs before the required time, a lower stress shall be selected and the minimum test
time will be obtained from the line through the stress/ time points given in Table 7.
TABLE-7
HYDROSTATIC STRENGTH (800C)-STRESS/
MINIMUM FAILURE TIME CORRELATION
PE-80 PE-100
Stress Minimum Failure Stress Minimum Failure
Mpa Time (h) Mpa Time (h)
4.6 165 5.5 165
4.5 219 5.4 233
4.4 293 5.3 332
4.3 394 5.2 476
4.2 533 5.1 688
4.1 727 5.0 1000
4.0 100 - -
8.2 PHYSICAL CHARACTERISTICS
When tested in accordance with the test methods as specified in Table 8 using the indicated
parameters, the fittings shall have physical characteristics conforming to the requirements
given in Table 8.
TABLE-8: PHYSICAL CHARACTERISTICS OF FITTINGS
Property Units Requirements Test Test Methods

Parameters
Thermal Minutes > 20 200 C (1) ISO TR 10837
Stability
Melt Mass-flow g/10 min 0.2 < MFR < 1.4 Condition 18 ISO 4440.1
Rate (MFR) and after
processing
maximum
deviation of +
20% of the value
measured on the
batch compound
Test may be carried out at 210 C providing that there is a clear correlation to the results at
200 C, in case of dispute the reference temperature shall be 200 C.

FITTINGS
8.3 TECHNICAL FILE
The manufacturer of the fittings shall make availability of a technical file (generally
confidential) with all relevant data to prove the conformity of the fittings to this specification. It
shall include all results of the type testing and shall conform to the specification relevant
technical brochure (e.g. ISO 12093 for electro fusion fittings).
The technical description of the manufacturer shall include the following information:
1. Field of appliance (pipe and fitting temperature limits SDRs and out of roundness).
2. Assembly instructions.
3. Fusion instruction (fusion parameters with limits).
4. For saddles and tapping tee
The means of attachment (tools and/ or under clamp).
The need to maintain the under clamp in position in order to ensure the
performances of the assembly.
For electrofusion fitting, the format of the technical brochure shall conform to ISO DIS 12093.
In the event of modification of the fusion parameters, the manufacturer shall ensure that the
joint conforms to this standard.
9.0 MARKING
Following information shall be embossed upto height of 0.15 mm onto the fitting and also in
the form of bar code:
a) The manufacturers identity

b) The size of the fitting in mm
c) Material and Designation
d) The date of manufacturer (code may be used)
e) Fusion time in seconds
f) Cooling time in minutes
g) Fusion parameters in BAR code
h) Lot Number
The information may be printed on a label associated with the fitting.
10.0 PACKING
The fittings shall be packaged in bulk or individually protected where necessary in order to
prevent deterioration. Whenever possible, they shall be placed in airtight plastic bags in card
board boxes or cartons.
The cartons and/or individual bags shall bear at least one label with the manufacturers name,
date of manufacturer, type and dimensions of the part, number of units in the box, and any
special storage conditions and storage time limits.

BALL VALVE
TECHNICAL SPECIFICATION
FOR
MEDIUM DENSITY POLYETHLENE BALL
VALVES

BALL VALVE
CONTENTS
1. SCOPE AND FIELD OF APPLICETION
2. REFERENCES
3. DEFINITIONS
4. GENERAL SPECIFICATION
5. MATERIAL PARTICULARITIES
6. VALVES GENERAL PARTICULARITIES
7. MECHANICAL CHARACTERISTICS FOR ASSEMBLED VALVES
8. MARKING
9. PACKAGING
10. DATASHEET OF BALL VALVE

BALL VALVE
1.0 SCOPE AND FIELD OF APPLICATION:
This General Technical Specification specifies the requirements for Ball Valves and its
component made from extruded or injected moulded polyethylene (PE) and which are
intended to be used for the Natural gas distribution systems where the operating pressure
(MOP) is 4 barg and operating temperature is 250C.
In addition, it specifies some general properties of the materials from which these valves
are made.
It applies to bi-directional valves with Electro fusion sockets intended to be fused with
polyethylene pipes.
This specification is limited to valves with a nominal diameter (do) up to and including 180
mm.
2.0 REFERENCES:
part 1: General
part 3: Fittings
part 4: Valves
part 7: Guidance for assessment of conformity
ISO CD 12176-4: Plastics pipes and fittings - Equipment for fusion jointing polyethylene
system - part 4: Traceability coding
ISO TR 13950: Plastics pipes and fittings - Automatic recognition systems for Electro
fusions.
3.0 DEFINITIONS:
3.1 VALVES
An obtruding device designed to stop or restore the gas flow by operating and closing
mechanisms.

BALL VALVE
3.2 EXTERNAL LEAK TIGHTNESS

The tightness of the body enveloping the space containing the gas, with respect to the
atmosphere.
3.3 INTERNAL LEAK-TIGHTNESS
The tightness between the inlet and the outlet of the valve, obtained by closing the
operating mechanism.
3.4 LEAK-TIGHTNESS TEST
Test to determine
The internal leak-tightness of the valves closing seat when closed and pressurized
from either side.
The external leak-tightness of the valve when half open.
3.5 INITIATING TORQUE
Torque required to initiate movement of the obturator.
3.6 RUNNING TORQUE
Torque required to achieve full opening or closing of the valve at maximum allowable
operating pressure.
3.7 LEAKAGE
Emission of gas through the body, sealing membrane or any other component of the valve.
4.0 GENERAL SPECIFICATION:
The present specification is based on the European Standards EN 1555 series prepared by
technical committee CEN/TC 155 plastic technical and ducting system.
The requirements of this General technical specification are chosen in order to guarantee a
high quality gas system which will respond to the European Standards for gas supply
systems.
The valves described in this General technical specification comply with the standard
PrENl555-4 and the complementary particular requirements or options of the present GTS.
The valves are intended to be use in gas distribution networks made of PE pipes and
accessories.
The valves are laid and welded.

BALL VALVE
5.0 MATERIAL PARTICULARITIES:
5.1 GENERAL
All parts of the valve in contact with the gas stream shall be resistant to the gas, its
condensates and other occurring substances such as dust.
All metallic parts of the PE valve shall resist to both internal and external corrosion.
5.2 PE COMPOUND FOR POLYETHYLENE VALVES BODIES
The PE compound from which the valve body, with electro fusion socket is made out,
shall conform to prENl555-1.
The PE valves bodies are PE 80 / PE 100 class made from below listed material are
forbidden:
a) Use of recycled materials
b) Mixture of different materials
c) Addition of complementary materials
5.3 SEALS
The seals shall be so mounted as to be resistant to normally occurring mechanical loads.

Creep and cold flow effects shall be taken into account. Any mechanism that puts a loading
on the seals shall be permanently locked. Line pressure shall not be used as the sole
means of seal activation.
The seals shall be homogeneous, without any inner crack, inclusion or impurities and
cannot contain any component that can alter the properties of the materials they are in
contact with and prevent the nonconformity of those materials with the present
specification.
Additives shall be distributed evenly.
The rubber seal rings shall comply with standard EN 682.
Other seals shall comply with the relevant standard and be suitable for gas service.
5.4 LUBRICANTS
Lubricants cannot have any adverse effects on the long term performance of the valve
parts.
6.0 VALVES GENERAL PARTICULARITIES:
6.1 TECHNICAL FILE
The manufactures of the valves-shall deliver for each type of valve a technical file which
includes:

BALL VALVE
Raw material used.

Drawings, dimensions and tolerances, including for the accessories.
Application range (temperature and pressure limits).
Running torque and initiating torque.
Pressure drop and flow diagram.
Test results and Data proving the conformity of the valve in accordance with prENl555-
4 and PrENl555-7.
The pipe elements used during valves testing.
The assembly pipes/valves realized during testing shall be in conformity with the
manufactures instructions and the extreme installation conditions.
For the test assembly due consideration should be taken regarding the fabrication
tolerances and the variation of the outside ambient temperature.
6.2 DESIGN
Design pressure of valve shall be in accordance with IS-14885.

The wall thickness of the PE valve body shall be equal or greater than the minimum
wall thickness of the corresponding SDR 11 series pipes.
Valves body and valves ends form an indivisible whole.
The operating mechanism and the stop wedges will be protected against water
intrusion.
The valve body is completely sealed.
6.3 APPEARANCE
The internal and external surfaces of valve shall be smooth clean and shall have no
scoring, cavities or other defects to an extra that would prevent non-conformity to the
present GTS or to the standard PrEN1555-4.
6.4 DIMENSIONS
The dimensions will be in conformity with the standard PrENl555-3 and PrENl555-4.
7.0 MECHANICAL CHARACTERISTICS FOR ASSEMBLED VALVES:
7.1 GENERAL
The valve shall have mechanical characteristics and be tested as specified in the standard
prEN1555-4.
7.2 RUNNING TORQUE
The running torque and the concept of the valve shall prevent the valve from being easily
operated (by hand) without an operating key. Running torque shall be as per standard
PrEN 1555-4.

BALL VALVE
7.3 INDIVIDUAL TEST (BATCH RELEASE TEST)
Before delivery, each valves will be individually tested for mechanical strength and leak
tightness as per standard prEN 1555-4.
A combined mechanic resistance and leak-tightness test shall be performed in conformity

with the prEN 1555-4.
By batch of valves a supplementary leak-tightness test (25 mbar) shall be performed in

conformity with the prEN 1555-4 on 3 valves taken at random.
7.4 PRESSURE DROP AT LOW PRESSURE
For natural gas, allowable pressure drop shall be as per the standard EN 12117.
8.0 MARKING:
At least the information given below shall be printed or formed directly on the valve:
a) Manufacturers name and/or trademark
b) Material and designation
c) Design application series
d) Nominal diameter
e) Internal fluid gas
f) Traceability code (valve and component) as per standard ISO/FDIS 12176-4
g) Number of the system standard. This information can be printed/formed directly on the
valve or on a label associated with the valve or on an individual bag
h) Production period, year and month
The marking shall stay legible during normal manipulation, storage and installation.
The marking shall not adversely influence the performance of the valve and prevent the
nonconformity of the valve.
9.0 PACKAGING:
The valve and its accessories shall be packaged individually in plastic bags in order to
prevent them from deterioration. The valves ends shall be protected with external caps.
The cartons and/or individual bags shall bear at least one label with the manufacturers
name, type and dimensions of the part number, number of units in the box and, any special
storage conditions and storage time limits.

BALL VALVE
10
10. DATA SHEET FOR MDPE BALL VALVES (WITHOUT STEM)
1 Service Natural Gas
2 Size ( Diameter) 63mm, 125mm, 180mm
3 Model Vendor to specify
4 Standard ASME B 16.40 / EN 1554-4
5 Process Class SDR 11

6 Design Pressure (Bar g) As per IS-14885
7 Operating pressure (Bar g) 4.0
8 Design Temperature (Deg. C) 60
9 Operating Temperature (Deg.C) 25
10 Location Underground / Aboveground
11 Pattern Full Bore

12 End Connection PE 80 / PE 100 grade material (Electrofusion type)
13 Stem Without Stem
14 Valve Design 1 piece construction

15 Ball position indicator Open / close indicator required
16 Mechanical stops For open / close limits required
17 Tests As per ASME B 16.40 / EN 1554-4

Standard Specification of MDPE Ball Valve

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TECHNICAL VOLUME

INDRAPRASTHA GAS LIMITED (IGL)

SUPPLY OF MDPE FITTINGS & BALL VALVE

TENDER DOCUMENT NO: xxxxxxxxxxx

VCS REFERENCE NO: xxxxxxxxxxxx

A 17.03.2017 ISSUED FOR REVIEW & COMMENT

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 1 of 30

2 TECHNICAL SPECIFICATION FOR FITTINGS A

TECHNICAL SPECIFICATION FOR BALL

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 2 of 30

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 3 of 30

MDPE FITTINGS & BALL VALVE

This document covers the technical specification for the enquiry.

S. No. Material Description UOM Total Quantity

A MDPE Ball Valve

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 4 of 30

5 SADDLE TAPP. MDPE 180X32MM PE80/PE100 NO 0

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Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 6 of 30

1. SCOPE AND FIELD OF APPLICATION

3. SYMBOLS & DEFINITIONS

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1.0 SCOPE AND FIELD OF APPLICATION

The material grades to be used are PE80 / PE100.

ELECTRO FUSION FITTING JOINTING

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 8 of 30

3.0 SYMBOLS & DEFINITIONS

3.1 SYMBOLS FOR ELECTRO FUSION FITTINGS

3.1.1 SYMBOLS FOR ELECTRO FUSION SOCKET FITTINGS

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3.1.2 SYMBOLS FOR ELECTRO FUSION TAPPING TEES

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3.2.1 Geometrical Definitions

a) Nominal diameter (dn / do):

b) Nominal wall thickness (en):

c) Mean inside diameter:

d) Out of roundness of the Socket:

e) Maximum out of roundness of the socket:

f) SDR value for a fitting:

g) Wall thickness (E) of a fitting:

3.2.2 Material Definition

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 11 of 30

b) Own Reprocessable Material:

3.2.3 Definition related to Material Characteristics

a) Lower Confidence Limit (LCL):

b) Overall Service (Design) Coefficient (C):

c) Minimum Required Strength(MRS):

d) Melt Mass Flow Rate (MFR):

3.2.4 Definitions Related to Service Conditions

b) Maximum Operating Pressure (MOP)

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MOP = (20 x MRS) / (C x (SDR-1)).

3.2.5 Definition on Design of Electrofusion Fittings:

a) Electro fusion Socket Fitting:

b) Electrofusion Saddle Fitting:

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 13 of 30

4.2 GRADE OF MATERIAL:

4.3 NOMINAL DIAMETER:

4.4.1 Polyethylene Compound:

TABLE-2: CHARACTERISTICS OF PE COMPOUND

Characteristics Units Requirements Test Test Methods

Rev. A SUPPLY OF MDPE FITTINGS & BALL VALVE Page 14 of 30

Characteristics Units Requirements Test Test Methods