Technical Submittal Union Dredgers and Marine Contracting

Hydro Dynamic Pipe Engineering FZ L.L.C

Ras-Al-Khaimah, United Arab Emirates

HDPE PIPE & FITTINGS

TECHNICAL SUBMITTAL

________________________________________________________________________ P.O.Box 85348 Dubai, United Arab Emirates

Tel: +971 (0)4 3219944 Fax: +971 (0)4 3250002 Email: [email protected] Web: www.hdpengineering.com

UGC/SM/PQF/11-001 R:00 (December, 2011)

mailto:[email protected]

http://www.hdpengineering.com/

CONTENTS:

1. Company Profile ……………………..………………………….. A

2. Licenses and Chamber of Commerce Registration .…….. B

3. Major Clients ……………………………………………..…....… C

4. Quality Plan and Certifications .………………………………. D

5. Manufacturing Processes ...…….……………………………… E

6. Joint Method Statements ………….……………………………. F

Butt Fusion, Electro Fusion Welding, Fabrication of HDPE,

Criteria and formats

7. Method Statement of Pressure Testing ………………………. G

8. Installation Process .……..…………….………………………… HI

9. Handling Storage & Transportation ..……..………………….. JK

10. HDPE Material Information ……………………….……………. L

11. HDPE Pipe Testing and compliance ………….….…….…….. M

12. Test Reports (National & International) ..……….….………… N

13. Approvals for Pipes & Fittings ..……………………..…………. O

14. HDPE Product Catalog ………………………………………….. PQ

Company Profile

UGC/SM/PQF/11/Rev01 Page 1 of 2

December 01, 2011

HYDRO DYNAMIC PIPE ENGINEERING

COMPANY PROFILE

History:

Hydro Dynamic Pipe Engineering FZ L.L.C. (HDPE) was established in 2007 is member of Union Group. Since

inception, the company has gained extensive growth through working with reputable customers across the

entire UAE. Hydro Dynamic Pipe Engineering factory is located in the Ras-al-Khaimah Free Zone and

occupies a site of 6780 square meters. Our continued focus on development led to the company obtaining

ISO 9001, ISO 14001 and OHSAS 18001 certifications in 2010.

Products:

Our production teams with 24 hours schedule a day ensure uninterrupted delivery of our products across

our customer base. Production techniques are being continuously monitored and reviewed to ensure we

are maintaining a high quality and technological standards.

We pride ourselves on assisting our customers in finding a solution that is right for them. We manufacture

a number of products including:

HDPE Pressure Pipes

HDPE Non Pressure Pipes (manufactured to our customers requirements)

HDPE Fittings

HDPE Welding Rods

In addition to manufacturing we are also able to custom fabricate HDPE items to suit specific applications

such as:

Fabricated Fittings (Elbows, Tees, Y’s)

Puddle Flanges


December 01, 2011

Sumps

Manholes

Customised PE Pipe Spools

Floating Pontoons, HDPE Floats

Galvanised Backing Rings

Rubber Gaskets

Our manufactured HDPE pipes are nationally and internationally approved for water, sewerage, oil and gas

applications.

Quality:

All our products are made from high quality PE100 material as this is a major contributing factor to the

quality of our end product. Our product lines are with compliance of D638, ISO 4427 & ISO 4437 standards.

In compliance with these standards, we apply stringent quality standards in all our operation.

A state of art laboratory supported by latest test equipments ensures the high quality products according

to specification of standards. These high standard, certifications and award for WRAS for polyethylene

pipeline systems used for potable water applications making HDPE a specialist in manufacturing High

Density Polyethylene solutions.

Our People:

Our team of professionals for production is well skilled, trained and capable of delivering products that

meets our customer’s specifications. Our technical team provides complete and continuous support to best

quality product all the time.

Licenses and Chamber of

Commerce Registration

Major Clients


December 01, 2011

HYDRO DYNAMIC PIPE ENGINEERING

Since establishment Hydro Dynamic has served a large number of Private, Public and Government Organisations including:

Sharjah Electricity and Water Authority (SEWA)

Union Dredgers and Marine Contracting

Consolidated Contracting Company

Culligan International

Emirates Trading Agency (ETA)

Rizzani De Eccher

National Marine Dredging Company (NMDC)

Wade Adams Construction

Perma Pipe Middle East

GASCO

ASCON

Nakheel

Corodex Industries

Al Jaber Group

Samsung Engineering and Construction

RAK Ceramics

SOS International

Al Habtoor Leighton

Utico FZE

etc.

Quality Plan and

Certifications


December 01, 2011

INTRODUCTION

The Quality, Safety & Environment policies manual including procedures, plans, guidelines and

formats and lower level documents describes the quality, health, safety and environment

management systems established to meet the ISO 9001, OHSAS18001 and ISO 14001

requirements. This plan describes the product requirements specific to PE pipes accordance to ISO

4427-1 and ISO 4427-2 standards with the objective of realizing quality products that can meet

both international standard specification and customer requirements. This plan establishes and/or

cross-refers the processes for quality related activities of the manufacturing process of the HDPE

product.

DESCRIPTION OF THE QUALITY SYSTEM

Hydro Dynamic Pipe Engineering is ISO 9001, OHSAS 18001 and ISO 14001 certified organization

from IIC as certification agency. The details with regard to the essential processes required for

managing, performing, monitoring and verifying the achievement of product quality are identified.

Also the processes are designed, determined and controlled.

All documents containing information critical to the operation of the quality management system

are identified and controlled. A large part of the documentation and records are in the form of

electronic media. Procedure for control of records is in place to safeguard and control that data.

The quality system documentation is based on a three level structure. These are constantly being

evaluated and reviewed to accommodate customer’s requirements and needs.

The documents include production and operations procedures for PE pipes production. Quality

control instructions detailing the testing and inspection procedures including that for PE pipes

conforming to ISO 4427-1&2.

QUALITY MANAGEMENT PLAN

The quality management plan covers the activities related to the range of products accordance to

ISO 4427 standards.

The quality management planning for PE pipes accordance to ISO 4427 standards include but not

restricted to the following:


December 01, 2011

Product Specification: the specification referred to include the technical specification of High

Density Polyethylene pipes to be used for buried water mains and services conforming to ISO 4427

standards.

Application: PE pipes are mainly used in underground pressure and gravity mains for the water

supply and industrial purposes. PE is a tough resilient material capable of withstanding the normal

rigors of pipe laying conditions.

Product certification: Most of the sizes of HDPE pipes, manufactured under ISO 4427. Hydro

Dynamic Pipe Engineering pipes are also approved by WRAS for effects on water quality of pipes

intended for the conveyance of water for human consumption.

Raw Material: the raw material used is generally PE 100 grade. These black compounds shall be

identified with the manufacturer’s name (when required), resin type and classification with

production batch reference. The other color for the pipes may include Blue or Black with blue

stripes. A material test certificate for the batch of the material supplied will be obtained from the

supplier indicating the suitability of the material for use at the design temperature and under

design pressures indicated for the pipe. Regrind materials may be used only in the pipes of 90mm

and above diameters. In such cases the regrind materials are derived by reworking the same grade

and type of the resin of the manufacturer. Care will be taken to avoid any foreign inclusions and

impurities mixing with the re-grind material that may distort the properties of the virgin resin.

Design: Pipe dimensional details are based on ISO 4427 standard. Hoop stress considered is 10 Mpa

for PE 100 material. Where applicable, suitable equipment dies and fixtures will be designed that

may be required to meet the processing requirement of the pipes.

Processing: The processing is done in accordance to ISO 9001 standard. The process is being

initiated by allocating a unique batch number (production order number) to each production. The

pre-production planning contains the requirements of product. Operations are controlled at critical

intervals by verification and constant monitoring by the machine operators and quality control

through specimen collection for inspections.

The operators working on the machines manufacturing these pipes both in night and day shifts are

highly skilled and conversant with the necessary process control techniques and requirements.


December 01, 2011

During extrusion, the pipes may be coiled or cut as straight lengths depending on the customer

requirement and diameter of the pipe. Generally, up to 125mm diameter pipes are coiled using

special coil frame.

Control of non-conformance products: In line monitoring, inspection, laboratory testing of samples

by Quality Control ensure consistency during production. Any defective material or product that

fails the prescribed inspection/ test are withdrawn and disposed of by moving them into rejected.

Pipe Identification: The pipes are identified by the information printed on them as per ISO 4427 or

customer’s requirements.

Inspection & Testing: The inspection and testing is done in through latest laboratory equipment

according to the requirement of ISO 4427 standard or customer requirements. Samples are sent to

quality control for testing and analysis that authorize continuity of production, reject or scrap

accordingly. Quality control is equipped with instruments to check and inspect the product as per

the specification. Measuring equipments that are part of product verification are calibrated. A

schedule is maintained by the maintenance administrator along with details of equipment showing

their operating range, accuracy, frequency, last calibrated, due dates, test required and other

relative information. Their party inspection can be arranged, if required by the customer.

Storage & Transportation: The product is suitably handled using the available resources of the

company so as to avoid damages. Care is taken to incorporate any customer requirements where

specified. PE pipes are generally coiled up to the size of 125mm (OD). Pipe with size above 125mm

are normally in straight length and are handled individually. If required by customer wooden pallets

(silos) can be used for stacking coils of pipes of small diameter. Straight lengths pipe up to a size of

200mm are bundled and strapped on every meter using plastic strap. Other big size pipes are

generally handled individually. Wide band webbed slings of polypropylene, nylon or similar

material are used for handling the pipe. While transport, pipes or stack of pies are arranged safely

on trucks avoiding crossing, bending and over stacking.


December 01, 2011

Quality Control Test Plan for ISO 4427 pipes: Sr. No.

Test Description Frequency of test

Controlling documents

Acceptance Criteria Responsible person

Verification Document

1. Material Properties (RM)

1.1 Carbon black content

Once/ supplier/ month

Work Instruction

2-2.5% QC Carbon Black Test Report

1.2 Carbon black dispersion

Once/ supplier/ month

Work Instruction

< grade 3 QC Carbon Black Test Report

1.4 Melt flow rate Once/ RM batch

MFR WI Max deviation of + 20% of the value specified by manuf.

QC MRF Test Report

2. General Characteristic (RM)

2.1 Appearance Twice/ shift Work Instruction

Pipe surfaces shall be smooth, clean and free from surface defects

QC Final Daily Inspection Report

2.2 Colour Approx every 1½ hours

Work Instruction

Blue, Black or Black with blue stripes

QC Final Daily Insp. Report

3. Geometrical Characteristics (Pipe)

3.1 Outside diameter Approx every 1½ hours

Work Instruction

ISO 4427-2; table 1 QC Final Daily Insp. Report

3.2 Wall Thickness Approx every 1½ hours

Work Instruction


3.3 Ovality 2 times/ shift Work Instruction


3.4 Length of the pipe 2 times/ shift Work Instruction

As stated by customer


3.5 Coiled pipe Once/ production run

Work Instruction

Internal dia of the coil > 18x OD


4. Mechanical Characteristics (Pipe)

4.1 Hydrostatic Strength 100hrs @ 20

oC

165hrs @ 80oC

See note 1)

Once/ production run

Work Instruction

No sign of rupture/ crack during test

QC Hydrostatic Pressure Test Report

5. Physical Characteristics (Pipe)

5.1 Elongation at break Once/ production run

Work Instruction

> 350% QC Tensile Test Report

5.2 Longitudinal reversion @ 110

oC

Once/ production run

Work Instruction

< 3%; No effect on surface.

QC Heat Rev. Test Report

5.3 Melt flow Index Once/ production run

Work Instruction

Change in MFR by processing + 20%

QC MFR Test Report

6. Marking (Pipe)

6.1 Printing on pipe Once/ production run

ISO 4427-2 As per ISO 4427-2 or customer spec.

QC N/A

Note: 1)

Material Hoop Stress (Mpa)

20oC 80

oC

PE 100 12.4 5.4

PE80 10.0 4.5

PE63 8.0 3.5

PE40 7.0 2.5

Records: Evidence adhering to the stipulated quality plan is maintained by the company in the form of records and can be provided to customer or external agencies as and when necessary.

Manufacturing

Processes


December 01, 2011

MANUFACTURING PROCESS

Currently a number of manufacturing techniques are used by Hydro Dynamic Pipe Engineering. These

include extrusion, rotation moulding, fabrication and machining. The process used will vary based on the

type of products and customer requirements.

Our pipes are manufactured using a process known as extrusion which can be summarized as follows;

The raw material is melted and homogenized in an extrusion machine. The melted material is pushed

through a die at a continuous and constant rate. The pipe is then slightly cooled and passed through a

vacuum calibrator tank to obtain the final dimensions required. The pipe is pulled throughout the entire

process at a rate directly equivalent to that of the extruder.

The freshly created pipe then travels through sealed water tanks to continue to cool down and reach final

hardness. The cooled pipe is then passed through a printing machine for batch number and other

pertinent information to be labeled on the pipe. Finally the pipe passes through the cutter which cuts the

pipe to the lengths requested by the customer.

Quality is at the forefront of HDPE’s production methodology. Since inception HDPE has gained ISO 9001,

14001 and OHSAS 18001 accreditation as well as a number of other approvals from third parties. This

mentality is ingrained into our production cycle right from the selection of only premium raw materials up

until testing of our finished product is carried out in our in-house lab. As a result of this emphasis Hydro

Dynamic Pipe Engineering has supplied significant amounts of HDPE pipe and products which are

manufactured in accordance with DIN8077, ISO4427, ISO4437 and to individual client’s specified

requirements.

Our staff are also trained in the custom fabrication of HDPE items designed to suit specific applications. In

addition we maintain a full fleet of butt fusion welding machines and can carry out on site jointing to meet

your needs.


December 01, 2011

MANUFACTURE OF HDPE PIPES

And then through the Sealed Water Vacuum Tank at 15-

20ºC

And then through the three (3) Water Vacuum Tank at

20ºC

Cooled Pipe will then pass through the Printing Machine

for Serial No

Scrap Materials will then be vacuumed off by the AR

Compressor

And then through the Rotating Cutting Machine

Transfer the Raw HDPE into the Heater by Vacuum Valve

Start Heating Process at

220ºC

Heated Raw Material will pass through Water & Air

Vacuum Tank at 15-22ºC

Start Heater 6 hours before production schedule

Assemble the Die Set-up while Pre-heat is going on

Fill in Raw HDPE into the Raw Material Box


December 01, 2011

PRE-PRODUCTION

1. Start Heater 6 hours before production schedule. The 500kva diesel generator should be filled with

diesel ensuring that the amount transferred from the diesel storage tank is marked as issued to

production on the Daily Production Report.

2. While pre-heating, assemble the Die Set-up according to specified size.

3. Using the forklift, fill in the Raw HDPE into the Hopper. The raw material should be allowed to dry

for the specified period. Pipe Grade PE100 raw materials should be used.

4. Complete the raw materials section of the Daily Production Report ensuring materials issued to

production section is completed.

PRODUCTION

5. Transfer the Raw HDPE into the Heater by Vacuum Valve.

6. Start the Heating Process at 220 ºC.

7. Raw HDPE Material will melts and passes through the die creating the pipe diameter required.

8. During the extrusion process the new pipe will begin extruding. The wall thickness should be

measured at this point to ensure compliance with the pressure requirements. This newly extruded

pipe should then be attached to an existing pipe of the same diameter to allow the new pipe to pull

through the next station.

9. The freshly created pipe will then travel through the Water & Air Vacuum Tank to cool down.

10. Further downstream the Pipe will then pass through the Sealed Water Vacuum Tank for cooling

11. And then through three (3) Water Vacuum Tanks for further cooling.

12. Cooled down pipe will then pass through the Printing Machine for the Batch Number and other

pertinent information to be labeled on the pipe.

13. Color of the printing should be WHITE, which differs from the color of the pipe which is BLACK.

14. The marking shall be such that it is legible without magnification.

15. Minimum required marking shall be in accordance to ISO 4427-2:2007 Table 6, with the frequency

of marking being less than once per meter.


December 01, 2011

ASPECT MARKING

Standard Number ISO 4427

Manufacturer’s Identification Hydro Dynamic Pipe Engineering FZ LLC, RAK, UAE

Dimensions Eg: ø 200

SDR Series Eg: SDR11

Material Designation PE 100

Pressure Rating Eg: PN16

Production Period (date or code) Eg: SHIFT ‘B = 070209

16. Finished product will then pass through the Rotating Cutting Machine and lengths of pipe will be

cut according to customer requirements.

POST PRODUCTION

17. Scrap Materials shall then be vacuumed off by the AR Compressor for storage and finally re-

processing.

Joint Method Statements

Butt Fusion Welding Electro Fusion Welding Fabrication of HDPE Criteria Formats


December 01, 2011

Purpose

This procedure aims is to describe the sequences of work operations for HDPE Butt Fusion Welding applied

according to standard and safe engineering practice.

Scope of Work

This procedure covers Butt Fusion Welding procedures and other related parameters of welding HDPE

pipes.

Procedure

Welding Procedure

Prior to commencement of welding the Site Foreman will ensure there is sufficient space to complete

welding operations. Appropriate signage/ warnings will be present to ensure site safety.

Welding machines and generators are kept on HDPE trays to reduce the impact of any oil spill.

The pipes are welded by using butt fusion welding technique. The pipes of generally 12m lengths are lifted

and transported to the welding machine by using a crane or manually depending on the diameter and

weight of the pipe involved. At first, the pipe sections to be joined are held axially on suitable supports and

clamped on the welding machine facing the pipe ends parallel to each other and the heater plate is

inserted between pipe ends in contact with both pipe ends. The interfaces to be welded are pressed

against the

Heater plate with the recommended welding pressures until the required melt pattern is obtained. Then a

reverse pressure is applied to remove the heater plate and the two pipe surfaces are allowed to come into

contact to form a weld. The pressure will be maintained until the molten interface cools and solidifies.

When the cooling time is completed, the clamps are removed and pipe is moved out from the machine

using suitable equipment.

Operation

1. The pipes will be loaded on the machines using a JCB or Crane 2. The welded Sections will be moved and the next pipe will be loaded on the machine. 3. The pipes are light in weight and may only need equipment as a result of the the length of the

pipes.


December 01, 2011

4. PPE Required : a. Light Cotton Gloves b. Safety Shoes c. Helmets d. Safety Goggles

QUALITY OF WELDS The Bend Test for each specific size and machine will be carried out to check the integrity of the welded

joint.

The welding will be carried out by Qualified and Experienced Welders, and the welding joints detail will be

logged in the Welding Sheet.

1. Welding Principle The principle of heat fusion is to heat two surfaces to a designated temperature, and then fuse them

together by application of a sufficient force. This force causes the melted materials to flow and mix,

thereby resulting in fusion. When fused according to the pipe and/or fitting and in accordance with a

proper procedures, the joint area is expected to become as strong as, or stronger than, the pipe itself in

both tensile and pressure properties. As soon as the joint cools to near ambient temperature, it is ready for

handling.

2. Butt Fusion

The most widely used method for joining individual lengths of polyethylene pipe and pipe to polyethylene

fittings is by heat fusion of the pipe butt ends. Trained operators and quality butt-fusion machines shall be

used to achieve quality joints.

The butt-fusion machines shall be capable of: • Aligning the pipe ends;

• Clamping the pipes;

• Facing the pipe ends parallel to each other

• Heating the pipe ends;

• Applying the proper fusion pressure that results in fusion.


December 01, 2011

Fig.1 Standard Butt Fusion Joint

Butt Fusion Parameter Most pipe manufacturers have detailed parameters and procedures to follow. The majority of them help

develop and have approved the PPI Technical Report TR-33 for the generic butt fusion joining procedure

for polyethylene pipe.

Generally the parameters indicated in the following table, shall be adopted as a minimum. The table could

be used as a guideline, for developing the required butt-fusion welding parameters.


December 01, 2011

Notes: i. These parameters apply to the butt fusion of PE80 or PE100 polyethylene materials

as specified in ASTM D2513. ii. These parameters may also apply to the butt fusion of PE80 to PE100. This may

result in slightly different bead formation without reducing weld quality (if in doubt refer to the pipe maker).

iii. Only pipes and fittings of the same diameter and wall thickness should be butt fused together.

iv. t = mean pipe wall thickness calculated from ISO 4427 min/max values, rounded to the nearest mm.

v. D = mean pipe outside diameter calculated from ISO 4427 min/max values, rounded to the nearest mm.

vi. Pressure calculation formula:

Where pipe annulus area = π (D - t) t

vii. For ambient temperature > 25o C, cooling time must be increased by 1 minute per o C above 25o C.

viii. For ambient temperature < 5o C, cooling time may be decreased by 1 minute per o C below 5o C.

Bead Removal Removal of the inner or outer bead of the joint is not allowed.

The main operations for Butt-Fusion Welding include:

Clamping: Pipe sections to be joined are held axially to allow all subsequent operations to take place.

Facing: Pipe ends shall be faced to established clean, parallel melting surfaces perpendicular to the centerline of the pipes.

Alignment: The pipe ends shall be aligned with each other to minimize mismatch or high-low of the pipe walls.

Heating: Melt pattern that penetrates in to the pipe shall be formed around both pipe ends.

Joining: The melts pattern shall be joined with a specified force. The force shall be constant around the interface area.

Holding: The molten joint shall be held immobile with a specified force until adequately cooled.


December 01, 2011

Butt Fusion Joint Quality Visual inspection is the most common joint evaluation method for all sizes of conventionally extruded

polyethylene pipe.

Fusion joining may be destructively tested to confirm joint integrity, operator procedure, and fusion

machine set-up. A field-performed destructive test is a bent strap test.

The bent strap test specimen is prepared by making a trial butt fusion, usually the first fusion of the day,

and allowing it to cool to ambient temperature. A test strap that is at least 150 mm or 15 pipe wall

thicknesses long on each side of the fusion, and about 25 mm or 1-½ wall thicknesses wide, is cut out of

the trial fusion pipe.

Fig.3 Bent strap test specimen

The strap is then bent so that the ends of the strap touch. Any disbandment at the fusion is unacceptable,

and indicates poor fusion quality. If failure occurs, fusion procedures and/or machine set-up should be

changed, and a new trial fusion and bent strap test specimen should be prepared and tested.

A test joint will be performed prior to commencement of the welding activities in accordance with this

procedure.


December 01, 2011

Preparation for Fusion

Ensure that the welding is carried out in dust free, wind and other foreign particles free

environment.

Fusion plate shall be cleaned with clean, lint free cotton cloth to remove dirt and dust on it, before

start of fusion.

Ensure correct surface temperature on the fusion plates before fusion.

When the pipes are in position ensure that sufficient length of the pipes protrudes beyond clamps

to allow for facing, heating and joining. Pipes shall be secured by tightening clamps, and by placing

on suitable supports.

The pipe ends are to be machined to ensure sureness and that the edges to be joined are clean and

free from ridges.

The main stages of fusion welding are as follows:

1. Bring pipe sections to be fused to be in contact with each face of the heater plate after inserting

heater plate between pipe ends. Move the pipes so that the heater plate comes into perfect

contact with both pipe ends. The interfaces to be welded shall be pressed against the heater

plate with the recommended heating pressure (same as welding pressure) value until even melt

pattern of 0.5 to 10 mm (depending on the wall thickness) forms around both pipe ends.

2. Soaking: Following formation of bead, initial heating pressure (same as welding pressure) shall

be reduced to minimum pressure. The pipe ends shall still be in contact with the heater.

NOTE: The Following schematic diagram gives a guideline for butt-welding: FIGURE -1: Butt Fusion Cycle: Principle Pressure/Time schematic diagram for the butt fusion welding P Pa1 Pf2 Pa2 t ta1 ta2 tf1 tf2 ta tu tf


December 01, 2011

Where: Pa1, Pa2 (MPa/Bar) Heating pressure, high and low Pf2 (MPa/Bar) Welding Pressure ta1, ta2 (s) Heating time with high and low pressure ta (s) Total heating time tf1 (s) Pressure build up time tf2 (s) Cooling time tf (s) Total cooling time tu (s) Change over time

3. Plate Removal: Snapping the pipes from the surface of the plate by reverse pressure allows the

heater plate to be removed. Next, reversal of pressure then allows the two surfaces to come

into contact and for a weld to form. Removal of heater plate shall be within the permitted

change over time.

4. Fusion: Application of welding pressure causes the molten surfaces to be forced to mate

together. The melt is pressurized and the surface regions are squeezed out from the joint

region. When it emerges from the interface the melt has no stiffness and so folds back to form a

bead.

5. Cooling: Upon bead formation the molten interface cools rapidly and solidifies. The pressure

shall be maintained during cooling until the weld has cooled sufficiently before allowing the

pipe to be removed from the welding machine in accordance with the approved butt fusion

procedure. On completion of the fusion, drop the pressure to zero and open the clamps prior to

removal of the section.

6. When the cooling time is completed, the clamps can be opened and the pipe moved out from

the machine. Rough handling or pressure testing of the pipe before it has cooled completely to

ambient temperature should be avoided. Welding operator shall ensure that the above

operations are carried out efficiently to produce good joints.

Equipment to be Used The Machines are Semi Automatic and are powered by generators. There is a sealed control box and has

no flame or open electrical points. There is no risk involved in welding of HDPE pipes. The clamping

arrangement is single and the welders are well experienced.


December 01, 2011

ANNEXURE I :

METHOD OF BUTT FUSION

Butt-Fusion Parameter

Notation Units Value Comments

Heater plate temperature

Degrees C

220±15

Pressure value: Bead up

P1 kPa 175±25

Insert this value in the formula (note 6), and add drag pressure

Approx. bead width after bead up

Mm 0.5 ± 0.1t

t = wall thickness (see note 4)

Bead up time T1 second

Approx. 6t

Varies with ambient Temperature

Pressure value: Heat soak

P2 kPa Drag only

Heat soak time

T2 second 15t

Max. change-over time

T3 second 3+0.01D D = pipe diameter see note 5).

Max. time to achieve welding pressure

T4 second 3+0.03D

Pressure should be increased smoothly using most of the time allowed to reach weld pressure.

Pressure value: Welding & Cooling

P3 kPa 175± 25

Insert this value in the formula (note 6), and add drag pressure

Welding & cooling time: t<15mm

T5 second 10 + 0.5t Time in clamps

Welding & cooling time: t>15mm

T5 second 1.5t Time in clamps

Min. bead width after cooling

Mm 3 + 0.5t Typical. (See note 2)

Max. bead width after cooling

Mm 5 + 0.75t Typical. (See note 2)


December 01, 2011

ANNEXURE II :

BUTT FUSION WELDING PARAMETER

Machine Ritmo Delta 315

Sr. No.

Pipe Size

Power Rating T

[◦C]

1 2 3 4 5

*P1 [bar]

Bead Width

‘A’

P2 [sec]

t2 [sec]

t3 max [sec]

t4 [sec]

*P5 [bar]

T5 [min]

1 315mm SDR 17 PN 10 200 +10◦C

44 2,4 6 224 10 11 44 22

2 250mm SDR 17 PN 10 200 +10◦C

28 2,0 4 178 8 10 28 18

Machine Ritmo Delta 500

Sr. No.

Pipe Size Power Rating T

[◦C]

1 2 3 4 5

*P1 [bar]

Bead Width

‘A’

P2 [sec]

t2 [sec]

t3 max [sec]

t4 [sec]

*P5 [bar]

T5 [min]

1 250mm SDR 17 PN 10 200 +10◦C

7 2,0 1 178 8 10 7 18

2 315mm SDR 17 PN 10 200 +10◦C

12 2,4 2 224 10 11 12 22

3 400mm SDR 17 PN 10 200 +10◦C

19 2,9 3 284 11 13 19 27


December 01, 2011

METHOD STATEMENT FOR ELECTRO FUSION WELDING


December 01, 2011

GENERAL

With electro fusion welding, an electrical resistance element is incorporated in the socket of the fitting

which, when connected to appropriate power supply, melts and fuses the material of the pipe and fitting

together.

The effectiveness of this technique depends on the attention to cleanliness, in particular the removal of

the contaminated surface of the pipe over the socket depth or an area equivalent to the saddle base.

Electro fusion fittings are available in the range 20mm to 500mm although larger sizes are now under

development.

Electro fusion saddles are available to fit all commonly used main sizes with sizes 20, 25 or 32mm service

connections. Outlet connections are also available up to a nominal size 180mm.

EQUIPMENT The control box input supply shall be from a nominal 220 volt generator. NO EXTENSION LEADS SHALL BE USED ON THE CONTROL BOX OUTLET CONNECTORS WARNING: Control boxes are not intrinsically safe and shall not therefore be taken into the trench. Pipe surface preparation tool capable of removing the contaminated surface of the pipe in excess of the

insertion depth before welding is attempted. The tool shall remove a layer 0.2. – 0.4mm thick from the

outer surface of the pipe preferably as a continuous strip over that length and round the pipe.

NOTE: Hand scrapers can be difficult to use effectively in trench conditions. Pipe clamps or other approved method for restraining, aligning, and re-rounding the pipes during the weld

cycle shall be used.


December 01, 2011

Pipe cutters including saw and saw guide. ELECTRO FUSION WELDING METHOD a. Preparation

Check that the pipe ends to be welded are cut square to the axis and any burrs removed.

Wipe pipe ends using clean, disposable, lint-free material to remove traces of dirt or mud, etc.

Mark the area over which the contaminated surface is to be removed, i.e. in excess of the

penetration depth, on each pipe to be welded by placing the socket of the bagged fitting alongside

the pipe end. Trace a line round the circumference at the appropriate distance from the pipe end

using a suitable marker.

DO NOT REMOVE THE FITTING FROM ITS PACKING AT THIS STAGE Connect the electro fusion control box input leads to the generator. Check that there is sufficient fuel for the generator to complete the joint. Check that reset stop button, if fitted on the control box, is in the correct mode. Using the pipe end preparation tool, remove the entire surface of the pipe uniformly, preferably as a

continuous swarf over the area identified, i.e. in excess of penetration depth.

b. Electro fusion Welding Procedure

Remove the fitting from its packaging and check that the bore of the fitting is clean and dry. If

necessary, dry it with clean, disposable, lint-free material and degrease with a clean cloth dampened

by a suitable solvent like acetone liquid.


December 01, 2011

NOTE 1: Isopropanol is a suitable cleaner for the material if permitted by the site health and safety

regulations.

Insert the pipe ends into the fitting. NOTE 2: It is recommended to mark pipe ends with an indelible pen to ensure pipe depth of entry is

maintained and a visible record retained when fusion is complete.

Using the pipe clamps, secure the pipes so that they cannot move during the fusion cycle. Check that

the pipe ends and the fittings are correctly aligned.

If applicable, remove the terminal caps from the fitting. Start the generator and check that it is functioning correctly. Make sure that the generator is providing required voltage (220V). Connect the control box output leads to the fitting terminal and check that they have been fully

inserted.

Switch on the control box where applicable. Commence the fusion welding procedure in accordance with the control box instruction and check

indicated welding time with time shown on fitting.

Scan the bar code magnetic card which is provided together with the welding socket. Details of the

welding socket will be displayed on the welding set.

Press the start button on the control box and check that the heating cycle is proceeding as indicated

by the displaying countdown.

On completion of the heating cycle, the melt indicators should have risen. If there is no apparent

movement of the melt indicators, the joint should be cut out and a new joint made.

If a satisfactory joint has been made, the joint shall be left in the clamps for the cooling time specified

on the fitting.

NOTE: If the fusion cycle terminates before completion of the countdown, check for faults as

indicated by the control box warning lights. Do not attempts a second fusion cycle if countdown of


December 01, 2011

the first cycle reached more than half of the total time require and for at least one hour after the first

attempt.

ELECTRO FUSION SADDLE WELDING METHOD

a. Preparation Expose the pipe onto which the tapping tee saddle is to be assembled. Clean the pipe over the general area on which the saddle is to be assembled using clean, disposable,

lint-free material and use clean water only.

Without removing the fitting from its packaging, place it over the required

b. Electro fusion Saddle Welding Procedure Position the fitting base onto the prepared pipe surface and install the saddle clamp. Remove the terminal caps from the fitting.

Check that there is sufficient fuel for the generator to complete the joint. Start the generator and

check that it is functioning correctly.

Connect the electro-fusion control box input leads to the generator.

Connect the control box output leads to the fitting terminals and check that they have been fully

inserted.

Switch on the control box if applicable.

Commence the fusion jointing procedure in accordance with the control box instructions and check

indicated joint time shown on fitting.

Press the start button on the control box and check that the heating cycle is proceeding as indicated

by the display count-down.

On completion of the heating cycle, the melt indicator should have risen. If there is no apparent

movement of the melt indicator, where incorporate, a new saddle joint should be made. Cut the tee

of the faulty joint from its base.

If a satisfactory joint has been made, the joint shall be left in the clamps for the cooling time specified on the fitting label.


December 01, 2011

NOTE: If the fusion cycle terminates before completion of the count-down, check for faults as

indicated by the control box warning lights. DO NOT attempt a second fusion cycle.

NOTE: DO NOT attempt to tap the pipe with the integral cutter for at least 10 minutes after

completion of the fusion cycle.

A well-made electrofusion saddle joint should have the following features:

The melt indicator should have operated where:

• There should be no melt flowing from round the saddle base;

• There should be evidence of pipe surface preparation round the saddle base.

The following features indicate faults during the assembly / fusion operation:

(1) Fusion indicator fails to operate

Causes:

(a) incorrect fusion time selected – too short ;

(b) control box out of specification – under voltage;

(c) fitting heating coil failure;

(d) incorrect fitting for size of main;

(e) top load too low on loading tool.

(2) Excess melt indicator or from saddle base

Causes:

(a) incorrect fusion time selected – too long;

(b) control box out of specification – over voltage;

(c) insufficient pressure from top loading assembly tool;

(d) time failure – too long;

(e) incorrect fitting for size of main;

(f) top load too high on loading tool.

(3) Inadequate fusion of saddle base on main

Causes:

(a) lack of pipe preparation;

(b) fitting heating coil failure.


December 01, 2011

MAINTENANCE, SERVICING AND CALIBRATION All equipment shall be well maintained and kept in a clean condition at all time, both in stores and on site.

The equipment shall be serviced and calibrated regularly. The frequency at which this is carried out will be

different for individual items of equipment and will also depend on usage, but should be at least once

every 6 months. Guidance shall be sought from the equipment manufacturer and a scheme of calibration

and servicing implemented. Particular attention shall be given to the control box and generator.


December 01, 2011

METHOD STATEMENT FOR FABRICATION OF HDPE ELBOW


December 01, 2011

PROCEDURE

1. Cut the pipe according the angle requirement.

2. Bring pipe sections to be fused to be in contact with each face of the heater plate after inserting

heater plate between pipe ends. Move the pipes so that the heater plate comes into perfect

contact with both pipe ends. The interfaces to be welded shall be pressed against the heater

plate with the recommended heating pressure (same as welding pressure) value until even melt

pattern of 0.5 to 10 mm (depending on the wall thickness) forms around both pipe ends.

3. Soaking: Following formation of bead, initial heating pressure (same as welding pressure) shall

be reduced to minimum pressure. The pipe ends shall still be in contact with the heater.

4. Plate Removal: Snapping the pipes from the surface of the plate by reverse pressure allows the

heater plate to be removed. Next, reversal of pressure then allows the two surfaces to come into

contact and for a weld to form. Removal of heater plate shall be within the permitted change

over time.

5. Fusion: Application of welding pressure causes the molten surfaces to be forced to mate

together. The melt is pressurized and the surface regions are squeezed out from the joint region.

When it emerges from the interface the melt has no stiffness and so folds back to form a bead.

6. Cooling: Upon bead formation the molten interface cools rapidly and solidifies. The pressure

shall be maintained during cooling until the weld has cooled sufficiently before allowing the pipe

to be removed from the welding machine in accordance with the approved butt fusion

procedure. On completion of the fusion, drop the pressure to zero and open the clamps prior to

removal of the section.

7. When the cooling time is completed, the clamps can be opened and the pipe moved out from

the machine. Rough handling or pressure testing of the pipe before it has cooled completely to

ambient temperature should be avoided. Welding operator shall ensure that the above

operations are carried out efficiently to produce good joints.

QUALITY OF WELDS

The Bend Test for each specific size and machine will be carried out to check the integrity of the

welded joint.

The welding will be carried out by Qualified and Experienced Welders, and the welding joints detail

will be logged in the Welding Sheet.


December 01, 2011

EQUIPMENT TO BE USED The Machines are Semi Automatic and are powered by generators. There is a sealed control box and has

no flame or open electrical points. There is no risk involved in welding of HDPE pipes. The clamping

arrangement is single and the welders are well experienced.

HDPE-PRO-GL-001/Rev 01

Page 1 of 1

17 Sep 2012

emin emax emin emax emin emax

16 1.6 0.0 13.0 0.07 1.6 0.0 13.0 0.07 1.6 0.0 13.0 0.10

20 1.6 0.0 17.0 0.10 1.6 0.0 17.0 0.10 1.9 2.3 16.0 0.10

25 1.6 0.0 22.0 0.12 1.9 0.0 21.5 0.10 2.3 2.7 20.4 0.18

32 1.6 0.0 29.0 0.16 2.0 2.3 27.9 0.20 3.0 3.4 26.2 0.29

40 2.0 0.0 36.0 0.25 2.4 2.8 35.2 0.31 3.7 4.2 32.6 0.45

50 2.0 2.3 46.0 0.32 3.0 3.4 44.0 0.47 4.6 5.2 40.8 0.69

63 2.5 2.9 58.0 0.48 3.8 4.3 55.4 0.75 5.8 6.5 51.4 1.09

75 2.9 3.3 69.2 0.69 4.5 5.1 66.0 1.05 6.8 7.6 61.4 1.53

90 3.5 4.0 83.0 0.99 5.4 6.1 79.2 1.52 8.2 9.2 73.6 2.20

110 4.2 4.8 101.6 1.45 6.6 7.4 96.8 2.24 10.0 11.1 90.0 3.26

125 4.8 5.4 115.4 1.87 7.4 8.3 110.2 2.87 11.4 12.7 102.2 4.23

140 5.4 6.1 129.2 2.36 8.3 9.3 123.4 3.59 12.7 14.1 114.6 5.26

160 6.2 7.0 147.6 3.09 9.5 10.6 141.0 4.69 14.6 16.2 130.8 6.91

180 6.9 7.7 166.2 3.85 10.7 11.9 158.6 5.92 16.4 18.2 147.2 8.73

200 7.7 8.6 184.2 4.77 11.9 13.2 176.2 7.31 18.2 20.2 163.6 10.80

225 8.6 9.6 207.8 5.99 13.4 14.9 198.2 9.28 20.5 22.7 184.0 13.60

250 9.6 10.7 230.8 7.41 14.8 16.4 220.4 11.40 22.7 25.1 204.6 16.70

280 10.7 11.9 258.6 9.24 16.6 18.4 246.8 14.30 25.4 28.1 229.2 21.00

315 12.1 13.5 290.8 11.80 18.7 20.7 277.6 18.00 28.6 31.6 257.8 26.60

355 13.6 15.1 327.8 14.90 21.1 23.4 312.8 23.00 32.2 35.6 290.6 33.70

400 15.3 17.0 369.4 18.80 23.7 26.2 352.6 29.00 36.3 40.1 327.4 42.80

450 17.2 19.1 415.6 24.30 26.7 29.5 396.6 36.80 40.9 45.1 368.2 54.30

500 19.1 21.2 461.8 30.00 29.7 32.8 440.6 45.30 45.4 50.1 409.2 66.90

560 21.4 23.7 517.2 37.70 33.2 36.7 493.6 56.90 50.8 56.0 458.4 83.80

630 24.1 26.7 581.8 47.70 37.4 41.3 555.2 71.90 57.2 63.1 515.6 106.00

710 27.2 30.1 655.6 60.50 42.1 46.5 625.8 91.40 64.5 71.1

800 30.6 33.8 738.8 76.70 47.4 52.3 705.2 116.00 72.6 80.0

900 34.4 38.3 831.2 97.00 53.3 58.8 793.4 147.00 81.7 90.0

1000 38.2 42.2 923.6 120.00 59.3 65.4 881.4 181.00 90.2 99.4

1200 45.9 50.6 1108.2 172.00 67.9 74.8

1400 53.5 59.0 1293.0 234.00 82.4 90.8

1600 61.2 67.5 1477.6 306.00 94.1 103.7

1800 69.1 76.2 105.9 116.6

2000 76.9 84.7 117.6 129.5

PN 10

WALL THICKNESSde kg/m

INSIDE

DIAMETER

WALL THICKNESSES AND INSIDE DIAMETERS OF HDPE PIPES

ISO 4427-2:2007

WALL THICKNESS INSIDE

DIAMETERkg/m

SDR 11

PN 16

WALL THICKNESS INSIDE

DIAMETERkg/m

PN 6.3

SDR 26

NOMINAL PRESSURE

PIPE SERIES

NOMINAL

SIZE OF PIPE

SDR 17

Method Statement of

Pressure Testing


December 01, 2011

1. SCOPE This document outlines the general hydrostatic pressure test applied to polyethylene pipeline and draws

attention to the possible problems of applying this test to PE pipelines. The principles of testing and the

importance of air removal are described.

2. PRINCIPLE The structural integrity of a pipeline is demonstrated by a pressure test, which is conducted after

installation and prior to placement into service.

The pipeline section under testing is filled with water followed by air bleeding and pressurized to the

specified pressure for the specified duration. If after a set time there is a pressure decrease, the volume of

water necessary to return the sealed system to the test pressure is then measured. The system is

considered to be leak free if the volume of water is less than the specified volume.

3. FACTORS RESPONSIBLE FOR VARIATIONS IN PRESSURE TEST RESULTS:

a. Length of the test section b. Presence of air in the pipeline c. Temperature changes d. Exposed area of pipeline e. Rate of pressure loading f. Range of test pressure imposed g. Relative movement of ‘mechanical’ fittings h. Efficiency of the bedding and compacted surround to resist pipe movement i. Diameter of the pipe j. Accuracy and efficiency of testing apparatus.

Careful planning and preparation of the test can reduce the influence of the factors identified above. Air

removal is a very important step which must be carried out without any ignorance

Note: refer informative note on air removal at the end of section

4. SITE PRESSURE TESTING The purpose of site pressure testing is to establish the integrity of the joining and installation. The

following general requirements should be considered before testing:

a. Water: Clean water free from air bubbles. The quantity of water needed to fill the internal volume

of the pipe test section may be estimated using:


December 01, 2011

Vm3 = 0.785 x 10-6 x Idmm2 x Lm

Where : Vm3 = Pipe section volume, m3

Idmm = Pipe inside diameter, mm and Lm = Test section length, m

b. Flow or load velocity: With valves at ends and high points open, the pipeline should be slowly filled

with water by gravity flow: if water is pumped, ensure to limit the flow velocity to 0.3 meter /

second to prevent surge or water hammer and air entrapment.

c. Provide an automatic Air Valve or air bleed as close to crown of the pipe as possible, at highest

points and at each end of the test section.

d. Pipeline test section: Pipelines should be tested in sections as convenient but lengths greater than

500 meters are not recommended.

e. Test Pressure Monitoring: The pressure measuring equipment shall be placed at the lowest point

of the testing section and pressure at the lowest point should not be more than that of test

pressure.

NOTE: Test pressure is a combination of pump pressure and the height (head) of water in the

pipeline. Therefore, test pressure is always monitored at the lowest elevation point in the section

where pressure is highest. Excessive test pressure can cause damage or pipeline failure.

f. Temperature:

i. The ambient temperature during the testing shall not be more than 30◦C. The concerned

personnel of Union Global shall be consulted for recommendations and safeguards when

testing pressure correction at higher temperature.

ii. The water and pipe temperature should be kept constant so that during the measurement of

the additional water, the temperature of the pipe walls, warmed perhaps by the sun, must not

vary more than ±1 ◦C. If necessary, the pipe section can be protected against direct sunlight.


December 01, 2011

g. Exposure: It is essential to backfill all the exposed sections of the pipeline before starting

hydrostatic testing. If possibe the test should be carried out started after 48 hours of covering the

excavation. Rapid temperature changes while testing will adversely affect the results.

h. All site pressure testing of Union Global HDPE pressure pipe should be carried out hydrostatically.

Pneumatic testing must not be carried out without prior consultation with the authorized

personnel of Union Global.

5. TESTING EQUIPMENTS Filling the pipeline: When the pipeline is filled, the water should be fed into the pipe at its lowest point

using a water pump, water main or in some other way ensuring that the filling speed does not exceed

0.3m/s.

Pressure Development: There must be a water pump or compressor or some other unit by means of

which the pressure can be developed and maintained at the desired level.

Pressure Measurement: For this purpose, a pressure gauge is needed with a minimum indicating accuracy of ±10 kPa. Air Release Valve: Air release valves are a must to bleed off the air entrapped in the pipeline before

proceeding for pressure testing. Air release valve(s) shall be used at all highest point(s) of the pipeline.

Measuring the Water Quantity: To determine the quantity of water to be added to the pipe system while

a test pressure is maintained, suitable measuring instruments (with an indicating accuracy of +0.1 / per

quantity of water added during the measuring period) are needed.

Measuring the temperature:

a. Water Temperature: Water thermometer (indicating accuracy ±1 ◦C.

b. Outdoor air thermometer: A thermometer with an accuracy ±1 ◦C.

6. TEST PROCEDURE Before filling and proceeding to test, sufficient time should be allowed for butt-fused joints to cool.

Slowly fill the pipe with water taking care to prevent surge and to evacuate all entrapped air in the

process. Ensure that water filling velocity does not exceed to 0.3 m/s. All entrapped air shall be released.


December 01, 2011

Allow the line for diametric expansion or stretching of pipeline to stabilize at its temperature for a period

of time depending upon the size of main and weather conditions. A minimum of 2-3 hours should be

allowed but testing the day after filling is to be preferred.

Testing is done in two phases.

a. For first phase gradually raise the pressure in the system to the nominal pressure of 2 Bar. From a

timing point of view, the test can be said to have started when the nominal pressure is reached and

the input to the system is disconnected. The system remains under pressure for a specified period

of ½ hour ±0.1 hours. Should there be any drop in pressure (minimum 20 kPa = 0.2 bar) during the

test, then water is pumped into the system to maintain the nominal pressure.

b. Again the phase two, gradually raise the pressure in the system to 3 Bar within a period of

preferably not more than 15 minutes and maintain this pressure for 1 hour.

Should there be any drop in pressure (minimum 20 kPa = 0.2 bar) during the test period, then

water is pumped into the system until the test pressure is reached.

After a period of 1 hour, should there be a drop in the test pressure, then a measured quantity of water is

pumped into the system until the nominal pressure is reached.

The pipe shall be judged to have passed the test satisfactory if the quantity of water required to restore

the test pressure does not exceed the amount calculated by the formula:

Q ≤ 0.02 x (Di – 1) liter / km. hour

Where Q = Amount of added water (if any) in liter per km per hr

D = ID of the pipe NOTE: This quantity may vary with water density and test temperature. A 10% variation in the added

water quantity may be considered as acceptable depending upon the testing temperature and water

density.

Air Removal in PE Pipeline: It is essential to remove as much air as possible from the pipeline before

pressurizing the test section. The following points should be considered to prevent problem associated

with incomplete air removal.


December 01, 2011

a. Wherever possible, the fill and test position should be located at the lowest point of the pipeline to

facilitate the expulsion of air as the pipeline is being filled. This position also registers the maximum

pressure head and permits easier control over the release of any test water. Adequate automatic

air release mechanism should be sited at all intermediate high points in the pipeline.

b. An automatic air bleed should also be incorporated as close to the crown of the pipe as possible at

the highest point at each end of test section.

c. Before filling the pipeline, all air venting system should be opened. It is assumed that automatic air

valves will have been installed at all high points of the pipe profile and these should operate

normally but consideration may be given to the temporary removal of the ball from the highest one

assist the expulsion of air. Where high test pressures are involved, consideration should be given to

isolation of the air valve to prevent damage to the ball.

d. The filling velocity should not exceed 0.3 m/s.

e. The introduction of a firm foam swab ahead of the water column may be helpful in some cases. e.g

where the pipeline undulates.

f. After ensuring that the pipeline is fully charged with water, all air vents should be closed.

Automatic air valves will normally self seal under pressure but they should be checked during the

test.

RETESTING In the event of a further test being required on the pipeline, such a test should not be attempted before

sufficient time has elapsed for the pipeline to recover from the previously imposed conditions. The

recovery time will depend upon individual circumstances but a period equivalent to 5 times the previous

total test period may be taken as a guide.

7. SAFETY DURING HYDROTESTING: The testing area should be barricaded and to be identified with a board or suitable mean. Safety

precautions in accordance with industrial rules should be followed and the personnel carrying out the


December 01, 2011

activity must be protected with safety guards. The following guidelines are recommended as the safety

precautions for hydro testing.

Wherever applicable, pipe trenches should be backfilled prior to testing. Before testing, joints are to be inspected and judged satisfactory. A test should not be conducted unless joints are sufficiently cooled after welding.

Where a test is to be applied to a section of a pipe with a free end, then it will be necessary to provide

temporary support against the thrust developed by the application of test pressure. The bearing area of

the temporary supports on surrounding soils must be sufficient to ensure that the maximum bearing

capacity of the soil is not exceeded.

Where test pressures are applied to pipelines not completely filled with water (i.e. pockets of entrapped

air) water hammer conditions may result. This is due to the pipeline flexing and the pockets of air (now

compressed) shifting position in the system. Pressure of considerable magnitude can occur with dramatic

consequences.

Particular care must be taken when filling the flexible pipelines laid to relatively shallow gradients. The

pipeline should always be filled from the lowest point.

Line valves, air valves and other appurtenances shall be removed or blanked off prior to testing. Automatic

air vacuum release valves should be installed at all ‘high spots’ in the pipeline.

Indications that the line is not completely filled with water or presence of air pockets are:

a. Excessive time for test pressure to be achieved.

b. Bouncing pressure gauge.

NOTE: If it is suspected that the line is not completely free from air then the test should be discontinued

and measures taken to purge the system.

8. REPAIRING Field pressure testing is a mechanism to check the integrity of pipeline components. In case of leakage or

damage to sections of pipeline, various methods can be used for repairing leakages or damage.


December 01, 2011

In general, the best way is for the damaged section to be cut out and replaced by a prefabricated

replacement unit or fittings. When failure or damage occurs in a welded joint, the original weld should be

removed entirely before rewelding.

9. EFFECT OF TEMPERATURE Polyethylene being a temperature sensitive material, ambient temperature conditions absolutely must be

taken into account when performing field pressure test. The hydrostatic pressure must be corrected

according to the prevailing temperatures. As a general rule, the test pressure (at a temperature >20◦C)

should be reduced as following:

Test Pressure (Tpt) = Tp20◦C x Ft Where Tp20◦C = Test pressure as specified @ 20◦C Ft (multiplier factor) is given as under:

Ambient Temperature (◦C) Multiplier factor Ft**

Up to 27 1.0

From 28 to 32 0.9

From 33 to 38 0.8

Above 41 *

NOTE: * - Concerned personnel of Union Global shall be consulted for pressure multiplier factor.

Installation Process


December 01, 2011

INSTALLATION PROCEDURES

HDPE pipe system is designed to make installation quicker, easier and more cost-effective.

Installation is part of the costing equation as ease of maintenance and the price of the pipe system

itself.

HDPE’s great advantage in installation is its lightness and flexibility coupled with its durability and

totally secures jointing methods. For all modern pipe laying techniques, whether in rehabilitation

work or the construction of new pipelines HDPE pipes usually provide the simplest, most economic

solution.

When polyethylene pipe is laid it may suffer damages. Precautions must be taken to reduce this,

although test work carried out has proved that scoring up to 10% of the pipe wall thickness will not

affect the performance of the pipe.

GENERAL POINTS ON TRENCH EXCAVATION

The pipe should be continuously supported over its entire length continuously on firm stable

material.

Pipe may be installed in a wide range of native soils. The pipe should be kept free from the

damages through stable and placed in such a manner as to evenly support.

The pipe embedment materials should be stable, sufficiently granular to be readily worked under

the side of the pipe to provide satisfactory, and readily compactable to achieve soil densities

specified by contract documents.

Initial backfill materials should be placed in compacted layers. All native and other materials in the

pipe embedment zone should be free from refuse, organic materials, cobbles, boulders, large rock

or stones or frozen soils. If soil from the excavation material is unsuitable, selected excavated

materials free from sharp particles or clean sand should be used.


December 01, 2011

If soil from the excavation material is unsuitable, selected excavated material free from sharp

particles or clean sand should be used.

The particle size of material in contact with the pipe should preferably be of size 5mm to 10mm

grade. Each soil layer should be sufficiently compacted to uniformly develop lateral passive soil

forces during the backfill operation.

To minimize deformation of thinner-walled pressure pipelines, such as used in irrigation, the

pipeline may be first filled with water, all air removed, and kept full during the backfill operation.

When installing pipe in locations where rapid movement of ground water may result in migration

of soil fines into, out of, or between layers of the embedment material, the bedding and back fill

should be of such gradation in particle size as to preclude this possibility. Vibratory methods are

preferred when compacting sand or gravels. Best results are obtained when the soils are in a nearly

saturated condition.

RECOMMENDED TRENCH COMPOSITION

Handling, Storage &

Transpiration


December 01, 2011

PIPE & PRODUCT HANDLING

Personnel handling pipe should apply care and attention always when handling pipe. Safety of

personnel shall also be ensured, this should not only be for the protection of the pipes.

Care should be applied to prevent dropping pipes onto hard or uneven surfaces.

Pipes should never be thrown from vehicles.

Pipes should never be dragged or rolled along with ground.

All possible care should be applied when loading pipes, where possible pipes should always be

unloaded individually.

Where pipe weight exceeds personnel handling weight capacity, rope or web slings should be used

with mechanical lifting equipments.

Metal chains, hooks or ropes should never be used.

PIPE & PRODUCT TRANSPORTATION

Vehicles transporting pipes should be free from sharp edges and have a flat bed.

Pipes should not be overhang the vehicle by more than 1 meter and shall be evenly supported over

their full length.

Where different sizes of pipe are to be transported together then larger diameter pipe should be

loaded first with the vehicle having side supports at no longer then 1.5 meter intervals.

All supports should be free from sharp edges.


December 01, 2011

PIPE & PRODUCT SITE STORAGE

Bundled Pipes:

Finished pipes should be stored on flat even ground able to withstand the weight of both, pipe and

the lifting apparatus.

Pipes should be kept away from sharp projections; stores or other jagged cut crops.

Bundle strapping should remain in position until such time that the pipe is to be used.

Height should not exceed three bundles.

LOOSE Pipes:

Where possible pipes should be stored on flat even ground able to withstand weight of pipes and

lifting apparatus.

Different sizes of pipes should be stored separately. Where this is not possible, larger and/or

thicker walled pipes should be placed at the bottom of the stack and pipe stacks should not exceed

3 meters in height.

Pipes should never be placed in contact with lubricating or hydraulic oils, gasoline, solvents or

other aggressive materials.

Pipes shall be kept away from intense heat.

Protection from Ultra-Violet:

A FIFO (first-in, first-out) stock rotation system of pipe and fittings usage should be adopted.

For hotter climates as experienced in the Gulf it is recommended that pipes should be kept under

cover at all times during storage – higher UV levels can otherwise ‘bleach’ the pipe. Covering also

protects against excessive heat build-up (which could lead to pipe deformation). Therefore, it is

recommended that pipes should be protected from direct sunlight whilst ensuring good ventilation,

storage in containers is not recommended.

HDPE Material

Information

HDPE Pipe Testing

and Compliance


December 01, 2011

HDPE PIPE TESTING PROCEDURES AND ROUTINES

According to testing standard & customer requirements, test techniques are used by Hydro

Dynamic Pipe Engineering Laboratory. The regular testing techniques are as follows:

a. Melt Flow Index test

b. Physical Dimensions and visual inspection (color/finishing)

c. Heat Reversion test

d. Tensile test

e. Oxygen Induction Time (OIT) test

f. Hydrostatic Pressure Test

OHSAS 18001 & ISO 14001

Test Reports

(National & International)

Report No: MA4438/R Page 2 of 6 pages

SUITABILITY OF NON-METALLIC PRODUCTS FOR USE IN CONTACT WITH WATER INTENDED FOR

HUMAN CONSUMPTION WITH REGARD TO THEIR EFFECT ON THE QUALITY OF THE WATER WRAS TESTS OF EFFECT ON WATER QUALITY (BS 6920: 2000)

HIGH TEMPERATURE TESTS (BS6920: PART 3: 2000)

INFORMATION AND GUIDANCE NOTE WATER REGULATIONS ADVISORY SCHEME The Scheme wishes to draw to the attention of product manufacturers and users that reports issued by accredited test laboratories do not of themselves constitute approval by the Scheme or the test laboratory. Only a letter from the Scheme, citing a Directory Reference Number, can be regarded as indicating approval. 1. SAMPLES FOR TESTING

General composition of product HDPE Trade name and reference of material BorSafe HE3490-LS Material manufacturer Borouge, Abu Dhabi, UAE Submitting organisation Hydro Dynamic Pipe Engineering FZ

LLC Component name/ref Hydro Dynamic Pipe Engineering

Fittings Component manufacturer Hydro Dynamic Pipe Engineering RAS-

AL-Khaimah, UAE Batch number of product PE04107456-3 Date of manufacture of product 25 September 2011 Description of sample black, opaque, matt plaque cut from a

stub end pipe fitting Method of manufacture of sample injection moulding Sampling procedure information not provided Surface area of test piece 20423mm² Number of articles constituting a test piece 1 Dimensions of test piece: length/width/ thickness: 110.68mm/59.29mm/21.47mm Calibration mark of test containers 1.5 litre Date of receipt of test samples 28 November 2011

Condition of samples on receipt satisfactory


Method of packaging cardboard box Conditions of storage of the samples between receipt and testing

as instructed in BS6920-2.1: 2000: clause 5.2

Proposed use of the product joints for pipelines for water

2. ODOUR AND FLAVOUR OF WATER

Extraction temperature - 60°C Date test commenced – 17 January 2012 Number of tasters in the taste panel – 3

Extract 1 (i) chlorine free test water:

Taster Odour description Flavour description Flavour

dilution number 1 nil nil <1 2 nil nil <1 3 nil nil <1

(ii) chlorinated test water:

Taster Odour description Flavour description Flavour dilution number

1 nil N/A N/A 2 musty N/A N/A 3 nil N/A N/A

Extract 2 (ii) chlorinated test water:

Taster Odour description Flavour description Flavour dilution number

1 nil nil <1 2 nil nil <1 3 nil nil <1

Comment - thus the sample of this product has been found to comply with the requirements of BS 6920: Part 1: clause 4 when extracted at 60°C.


3. APPEARANCE OF WATER

Extraction temperature – 60°C Date test commenced – 14 February 2012 Extract 1

Colour (Hazen units)

Turbidity (Formazine nephelometric units)

Test container (product) <5 0.15 Blank <5 0.1 Net Increase nil 0.05

Comment - thus the sample of this product has been found to comply with the requirements of BS 6920: Part 1: clause 5 when extracted at 60°C.

4. GROWTH OF AQUATIC MICROORGANISMS

Date test commenced – 29 November 2011 Mean dissolved oxygen differences -

Test container (product) 0.5mg/l Negative reference (glass) sample 0.0mg/l Positive reference (wax) sample 6.7mg/l Mean dissolved oxygen concentration of the negative control 8.1mg/l

Note - At the end of this test the test piece showed no changes in colour and appearance. Comments - thus the sample of this product has been found to comply with the requirements of BS 6920: Part 1: clause 6.


5. THE EXTRACTION OF SUBSTANCES THAT MAY BE OF CONCERN TO PUBLIC HEALTH

Extraction temperature - 60°C Date test commenced – 14 February 2012 Extracts were tested using African Green Monkey Cell Line (VERO ATCC CCL 81)

Extract Growth of cell tissue

(monolayer) Reagent blank healthy, confluent

Zinc Sulphate validation solution

(cytotoxic) cell death

sample healthy, confluent

Comment - thus the sample of this product has been found to give a non-cytotoxic response and therefore it has been found to comply with the requirements of BS 6920: Part 1: clause 7 when extracted at 60°C.


CONCLUSION The sample of the product referred to in this report has been tested in accordance with the methods specified in BS 6920: Part 2: 2000 “Suitability of non-metallic products for use in contact with water intended for human consumption with regard to their effect on the quality of the water: Methods of test” (including High Temperature Tests in accordance with BS 6920: Part 3: 2000) and the requirements of the Water Regulations Advisory Scheme ‘Guidance on the Requirements for Approval of Non-Metallic Materials in Fittings: Appendix A: version 2.8 April 2007’ This product has satisfied the criteria set out in BS 6920: Part 1: 2000 “Specification” and thus complies with the requirements of the Water Regulations Advisory Scheme Tests of Effect on Water Quality (BS 6920: 2000): Odour & Flavour of Water / Appearance of Water / Growth of Aquatic Microorganisms / Cytotoxicity / High Temperature Tests (60ºC). NO OTHER TESTS WERE UNDERTAKEN ON THIS PRODUCT N.B The results specified in this report relate only to the sample of the product submitted for testing.

Any changes in the nature or source of ingredients and the process of manufacture or application could affect the suitability of the product for use in contact with potable water.

Materials and products intended for use by a public water supply company in the preparation or conveyance of water may need to satisfy more comprehensive toxicological requirements as set specified by the Drinking Water Inspectorate. These additional requirements are necessary to ensure legal compliance with Regulation 31 of Water Supply (Water Quality) Regulations 2000. NOTE FOR WRAS The tests carried out on the sample of this product are based upon ‘WRAS Accredited Laboratories – Operating Procedures: WRAS MAT 3’ WRAS Audit & Reduced Testing Procedures, Table 1; Change in manufacturing site to another country with any ingredients from a local supplier/producer. Previous testing was carried out under our WRAS listing number 1110518. This report is for the exclusive use of Intertek's Client and is provided pursuant to the agreement between Intertek and its Client. Intertek's responsibility and liability are limited to the terms and conditions of the agreement. Intertek assumes no liability to any party, other than to the Client in accordance with the agreement, for any loss, expense or damage occasioned by the use of this report. Only the Client is authorized to permit copying or distribution of this report and then only in its entirety. Any use of the Intertek name or one of its marks for the sale or advertisement of the tested material, product or service must first be approved in writing by Intertek. The observations and test results in this report are relevant only to the sample tested. This report by itself does not imply that the material, product, or service is or has ever been under an Intertek certification program

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Technical Submittal Union Dredgers and Marine Contracting

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Transcript of Technical Submittal Union Dredgers and Marine Contracting